Blastmax 50 Eng

BLASTMAX
SERIES 50
OPERATION AND MAINTENANCE MANUAL
MANUAL 61173682M(R03)
NOTICE
This document contains subject matter in which KMT Aqua-Dyne 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 Aqua-Dyne 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 AQUA-DYNE 2010
KMT Aqua-Dyne 635 West 12th Street POB 231 Baxter Springs, KS 66713-0231 Phone: Fax: (800) 826-9274 (620) 856-5050
611453421 1-2013/Rev 02
TABLE OF CONTENTS
Title Page Notice Table of Contents Appendix
Section
1
Page
Introduction ....................................................................................................... 1-1 Overview ................................................................................................ 1-1 Safety ..................................................................................................... 1-1 Lockout/Tagout Procedure..................................................................... 1-1 Warning Labels ...................................................................................... 1-2 Emergency Medical Treatment .............................................................. 1-5 1.3 Worldwide Product Support .................................................................. 1-5 1.4 Spare Parts ............................................................................................. 1-6 Terms and Conditions of Sale 1.1 1.2
Operation ........................................................................................................... 2-1 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Overview ................................................................................................ 2-1 Transporting ........................................................................................... 2-1 Before Starting the System .................................................................... 2-1 Startup .................................................................................................... 2-2 Proper Operation .................................................................................... 2-3 Decommissioning .................................................................................. 2-4 System Storage....................................................................................... 2-4 Cold Weather Storage ............................................................................ 2-5 Startup after Storage .............................................................................. 2-5 Overview ................................................................................................ 3-1 General Safety Guidelines ..................................................................... 3-1 Operational Safety ................................................................................. 3-2 Pressure Relief Devices ......................................................................... 3-3 High Pressure Hose and Lance Assemblies ........................................... 3-4 Control Gun and Control Device Safety ................................................ 3-5 Rigid Tube Cleaning Lance Safety ........................................................ 3-6 Flexible Tube Cleaning Lance Safety .................................................... 3-7 Nozzles................................................................................................... 3-8 Personal Protective Equipment .............................................................. 3-8
Safety Guidelines ............................................................................................... 3-1 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9
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Maintenance Guidelines ................................................................................... 4-1 4.1 Overview ................................................................................................ 4-1 Daily Inspection ..................................................................................... 4-1 Monthly Maintenance ............................................................................ 4-2 High Pressure Fittings and Connections ................................................ 4-2 Filters and Strainers ............................................................................... 4-3 Nozzles, Holders and Lance Connections ............................................. 4-3 Trigger and Valve Controls ................................................................... 4-3 High Pressure Hoses .............................................................................. 4-3 Hydrostatic Testing ................................................................................ 4-3 Proper Hose Storage .............................................................................. 4-5
4.2 4.3 4.4 4.5 4.6
5 6
Power End Assembly ........................................................................................ 5-1 High Pressure Fluid End Assembly ................................................................. 6-1 6.1 6.2 6.3 6.4 6.5 6.6 Maintenance Overview .......................................................................... 6-1 Torque Specifications ............................................................................ 6-2 Valve Assemblies................................................................................... 6-3 Barrel Assemblies .................................................................................. 6-5 Packing Assemblies ............................................................................... 6-7 Low Pressure Seal Assemblies .............................................................. 6-8 Plungers.................................................................................................. 6-9 Overview ................................................................................................ 7-1 Troubleshooting Guide .......................................................................... 7-2 Service Connections............................................................................... 8-1 Lubrication Specifications ..................................................................... 8-1 Torque Specifications ............................................................................ 8-2 Water Quality Guidelines ...................................................................... 8-3 Nozzle Size Selector Chart .................................................................... 8-4 Overview ................................................................................................ 9-1
Troubleshooting ................................................................................................ 7-1 7.1 7.2
Specifications ..................................................................................................... 8-1 8.1 8.2 8.3 8.4 8.5
Parts List ............................................................................................................ 9-1 9.1
APPENDIX
Exhibit
Material Safety Data Sheets
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SECTION 1 INTRODUCTION
1.1 Overview
The KMT Aqua-Dyne Series 50 triplex positive displacement, plunger pump systems are designed and manufactured to operate in continuous service at a related flow and pressure. Adhering to the recommended procedures for operation and maintenance outlined in this manual will ensure optimum benefit is obtained from the high quality components used in the design and construction of Aqua-Dyne pumps and systems. The Series 50 is a compact mobile design pump for applications that require high pressure at lower flow rates, such as hydrostatic testing. Pressures range from 3,000 to 40,000 psi (207 to 2,758 bar); with horsepower ranges from 5 to 50.
1.2
Safety
All personnel operating, servicing or working near the equipment shall adhere to the following safety precautions. Only trained, qualified personnel shall service and maintain the equipment. The pump operator shall practice and promote safety at all times to avoid potential injury and unnecessary downtime. The work area around the pump shall be clean and free of debris and oil spills. 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 pump.
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.
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Section 1 Introduction
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 OFF button or turning the ignition key to OFF. 2. Electric Motor Disconnect, lockout and tag the power source Bleed water pressure at the filter assembly and air pressure at the air tank
3. Diesel Engine Remove the key from the ignition Bleed water pressure at the filter assembly and air pressure at the air tank
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 1-2 describes the necessary precautions and provides the part number required to order replacement labels. Table 1-2 Warning Label Precautions The poser source for electric units can present an electrical shock hazard. 1 Always disconnect and lockout the power source on electric units before performing any type of maintenance
P/N 05114962
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Table 1-2 Warning Label Precautions The surface of high pressure water and pneumatic components become hot during normal operation. Failed, or failing components, can become extremely hot during operation.
P/N 05114970
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. 3
P/N 80082209
High pressure water and/or air pressure can remain in the system even when the pump has been shut off. Bleed water pressure at the filter assembly and air pressure at the air tank.
P/N 05098017
All personnel involved in the installation, operation and/or service of the pump 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
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Table 1-2 Warning Label Precautions Safe operation of the unit and accessories must be followed to prevent injury. 6
P/N S25561-74
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.
NOTE 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.
Medical Alert
This card is to be carried by personnel working with high pressure waterjet equipment. Obtain medical treatment immediately for ANY high pressure waterjet injuries. KMT Aqua-Dyne Inc. 635 West 12th Street Baxter Springs, KS 66713 (620) 856-2151
This person has been working with water jetting at pressures to 40,000 psi (276 Mpa, 2758 bar, 2812 Kg/cm2) with a jet velocity of 2,434 fps (742 mps). Foreign material (sand) may have been injected with water. Unusual infections with microaerophilic organisms occurring at lower temperatures have been reported, such as gram negative pathogens as are found in sewage. Bacterial swabs and blood cultures may therefore be helpful. This injury must be treated as an acute surgical emergency and be evaluated by a qualified surgeon. Circulation 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.
1.3
Worldwide Product Support

The KMT Aqua-Dyne Customer Service Department is available to answer your questions regarding equipment installation and service. Technical assistance is available by phone and onsite 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. Periodic training sessions are also conducted at KMT Aqua-Dyne designated locations. Contact the KMT Aqua-Dyne Customer Service Department for additional information. USA Customer Service Department KMT Aqua-Dyne Inc. PO Box 231 635 West 12th Street Baxter Springs, KS 66713 USA Phone: (800) 826-9274 Fax: (620) 856-2242 Email: wj.service@kmtwaterjet.com Email: wj.parts@kmtwaterjet.com USA Customer Service Department KMT Aqua-Dyne Inc. PO Box 231 635 West 12th Street Baxter Springs, KS 66713 USA Phone: 713-864-6929 Fax: 713-864-0313 Email: sales@aqua-dyne.com
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1.4
Spare Parts
KMT Aqua-Dyne 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.
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Terms and Conditions of Sale

1. General
The Terms and Conditions of Sale outlined herein shall apply to the sale by KMT Aqua-Dyne Inc. (hereinafter referred to as Company) of products, equipment and parts relating thereto (hereinafter referred to as Equipment). Unless prior written agreement is reached, it shall be understood that the Company's proceeding with any work shall be in accordance with the terms and conditions outlined herein The Company will comply with applicable laws and regulations in effect on the date of the Company's proposal as they may apply to the manufacture of the Equipment. Compliance with any local governmental laws or regulations relating to the location, use or operation of the Equipment, or its use in conjunction with other equipment, shall be the sole responsibility of the Purchaser.
6. Set Offs
Neither Purchaser nor any affiliated company or assignee shall have the right to claim compensation or to set off against any amounts which become payable to the Company under this contract or otherwise.
7. Patents
The Company shall defend any Suit or proceeding brought against the Purchaser and shall pay any adverse judgment entered therein so far as such suit or proceeding is based upon a claim that the use of the Equipment manufactured by the Company, and furnished under this contract constitutes infringement of any patent of the United States of America, providing the Company is promptly notified in writing and given authority, information and assistance for defense of same; and the Company shall, at its option, procure for the Purchaser the right to continue to use said Equipment, or to modify it so that it becomes non-infringing, or to replace the same with non-infringing equipment, or to remove said Equipment and to refund the purchase price. The foregoing shall not be construed to include any agreement by the Company to accept any liability whatsoever in respect to patents for inventions including more than the Equipment furnished hereunder or in respect of patents for methods and processes to be carried Out with the aid of said Equipment. The foregoing states the entire liability of the Company with regard to patent infringement.
2. Title and Risk of Loss

Title and risk of loss or damage to the Equipment shall pass to the Purchaser upon tender of delivery F.O.B. manufacturing facility unless otherwise agreed upon by the parties, except that a security interest in the Equipment shall remain in the Company, regardless of mode of attachment to realty or other property, until full payment has been made therefor. Purchaser agrees upon request to do all things and acts necessary to perfect and maintain said security interest and shall protect Company's interest by adequately insuring the Equipment against loss or damage from any cause wherein the Company shall be named as an additional insured.
8. Warranty
The Company warrants that the Equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months (based on a 40 hour week) from the date of placing the Equipment in operation or eighteen months from the date of shipment, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the company within said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such Equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without the Company's prior written approval. The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited to those specifically stated within the Company's proposal. Unless responsibility for meeting such performance warranties are limited to specified shop or field tests, the Company's obligation shall be to correct in the manner and for the period of time provided above. THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities, whether based on contract warranty, negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.
3. Assignment
Neither party shall assign or transfer this contract without the prior written consent of the other party. The Company however shall be permitted to assign or transfer, without the prior written consent of the Purchaser, the Company's right to receive all or any portion of the payment due from the Purchaser under this contract.
4. Delivery and Delays

Delivery dates shall be interpreted as estimated and in no event shall dates be construed as falling within the meaning of "time is of the essence". The Company shall not be liable for any loss or delay due to war, riots, fire, flood, strikes or other labor difficulty, acts of civil or military authority including governmental laws, orders, priorities or regulations, acts of the Purchaser, embargo, car shortage, damage or delay in transportation, inability to obtain necessary labor or materials from usual sources, faulty forgings or castings, or other causes beyond the reasonable control of the Company. In the event of delay in performance due to any such cause, the date of delivery or time for completion will be adjusted to reflect the actual length of time lost by reason of such delay. The Purchaser's receipt of Equipment shall constitute a waiver of any claims for delay.
5. Taxes
The price does not include any present or future Federal, State, or local property, license, privilege, sales, use, excise, gross receipts or other like taxes or assessments which may be applicable to, measured by, imposed upon or result from this transaction or any services performed in connection therewith. Such taxes will be itemized separately to Purchaser, who shall make prompt payment to the Company. The Company will accept a valid exemption certificate from Purchaser, if applicable. If such exemption certificate is not recognized by the governmental taxing authority involved, Purchaser agrees to promptly reimburse the Company for any taxes covered by such exemption certificate which the Company is required to pay.
KMT Aqua-Dyne, Inc. (AD 101) 10-2006
Terms and Conditions of Sale
The Purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such use of Equipment will be at the Purchaser's sole risk and liability.
10. Nuclear Liability

In the event that the Equipment sold hereunder is to be used in a nuclear facility, the Purchaser shall, prior to such use, arrange for insurance or governmental indemnity protecting the Company against liability and hereby releases and agrees to indemnify the Company and its suppliers for any nuclear damage, including loss of use, in any manner arising out of a nuclear incident, whether alleged to be due, in whole or in part to the negligence or otherwise of the Company or its suppliers.
9. Limitation of Liability
THE REMEDIES OF THE PURCHASER SET FORTH HEREIN ARE EXCLUSIVE, AND THE TOTAL LIABILITY OF THE COMPANY WITH RESPECT TO THIS CONTRACT OR THE EQUIPMENT AND SERVICES FURNISHED HEREUNDER. IN CONNECTION WITH THE PERFORMANCE OR BREACH THEREOF, OR FROM THE MANUFACTURE, SALE, DELIVERY, INSTALLATION, REPAIR OR TECHNICAL DIRECTION COVERED BY OR FURNISHED UNDER THIS CONTRACT, WHETHER BASED ON CONTRACT WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE, SHALL NOT EXCEED THE PURCHASE PRICE OF THE UNIT OF EQUIPMENT UPON WHICH SUCH LIABILITY IS BASED. THE COMPANY AND ITS SUPPLIERS SHALL IN NO EVENT BE LIABLE TO THE PURCHASER, ANY SUCCESSORS IN INTEREST OR ANY BENEFICIARY OR ASSIGNEE OF THIS CONTRACT FOR ANY CONSEQUENTIAL, INCIDENTAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES ARISING OUT OF THIS CONTRACT OR ANY BREACH THEREOF, OR ANY DEFECT IN, OR FAILURE OF, OR MALFUNCTION OF THE EQUIPMENT HEREUNDER, WHETHER BASED UPON LOSS OF USE, LOST PROFITS OR REVENUE, INTEREST, LOST GOODWILL, WORK STOPPAGE, IMPAIRMENT OF OTHER GOODS, LOSS BY REASON OF SHUTDOWN OR NONOPERATION, INCREASED EXPENSES OF OPERATION, COST OF PURCHASE OF REPLACEMENT POWER OR CLAIMS OF PURCHASER OR CUSTOMERS OF PURCHASER FOR SERVICE INTERRUPTION WHETHER OR NOT SUCH LOSS OR DAMAGE IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE.
11. Governing Law

The rights and obligations of the parties shall be governed by the laws of the State of Delaware excluding any conflicts of law provisions. The United Nations Convention on Contracts for the International Sale of Goods shall not apply to this agreement.
12. Export Control

The Companys products are U.S. origin items and subject to U.S. export control laws, including the Export Administration Regulations. Customer agrees that it will comply with U.S. export control laws and will not export, re-export, transfer, re-transfer, sell, re-sell, otherwise divert Company products contrary to U.S. law. Customer further agrees that it will obtain all required export licenses.
13. Execution
The Company shall not be bound by any contract or any modification thereto until approved in writing by an officer of the Company. The contract, when so approved shall supersede all previous communications, either oral or written.
KMT Aqua-Dyne, Inc. (AD 101) 10-2006
SECTION 2 OPERATION
2.1 Overview
Commissioning requirements and procedures are detailed in this section. These procedures require a thorough understanding of the individual components, safety issues, and the overall operation of the system. All personnel involved in the operation and/or service of the system must carefully review this manual prior to commissioning and operating the machine. The Technical Service Department at KMT Aqua-Dyne is available to assist in the commissioning and operation process. Service and repair training for maintenance personnel is also available.
2.2
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 unit. The center of gravity is located at approximately the location of the lifting eye if so equipped. The forklift should be positioned accordingly. When the machine has been removed from the crate, note the position of the fork pockets on the bottom of the machine if so equipped. The pockets are positioned in relationship to the center of gravity to balance the weight on the forklift. Trailer units should be transported based on the type of hitch provided and the weight rating of the unit. The unit should only be transported with the water and fuel tanks empty.
2.3
Before Starting the System

Prior to starting the system review the manufacturers manuals included in the appendix covering the operation of the engine and drive train. 1. Set unit on a level surface to ensure that oil in the power end reaches the crankshaft main bearings. 2. Check oil and coolant levels in the pump and engine. Refer to Section 11, Specifications for information regarding power end lubrication. Refer to the engine manual for system component lubrication. 3. If the pump has an oil level shutdown switch, set the shutdown trips 1/2 inch above and 1 inch below the dipstick Hi-Lo level marks. 4. Inspect battery cables and hoses to ensure they are tight and secure.
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Section 2 Operation
5. Check fuel tank levels on engine powered units. Check engine power take off and drive train for tension and lubrication, see the manufacturers manual in the appendix. Check charge pump drives, if applicable. 6. Ensure the plunger and intermediate rod connections are tight. 7. Verify all bolts are torqued to the specified level. 8. Verify connections on the suction and discharge manifolds are tight and do not leak.
Do not attempt to tighten high pressure connections when the system is pressurized. Remove all pressure from the system before tightening connections.
9. Ensure the supply water and the filters and strainers are clean. 10. Verify the pressure rating stamped on the application tag for the pump matches the pump speed, plunger size, engine horsepower and the accessories to be used with the unit. 11. If supplied, verify the pressure relief valve is set 10 to 15 percent above the specified maximum working pressure. 12. Ensure the supply water line to the pump is airtight. Air entering the suction side, supply line will cause severe knocking and cavitation of the pump. 13. Attach a pressurized supply water line to the pump system inlet connector, 30 psi (1.4 bar) minimum or 80 psi (5.5 bar) minimum for 40,000 psi (2,758 bar) applications. The inlet supply line must be sized to flow at least double the GPM to be pumped from the system. NOTE Do not gravity the pump. Fluid supplied to the suction side must be pressurized to help guard against cavitation damage.
14. Check to ensure supply water is flowing to the system.
2.4
Startup
1. Disengage the clutch on diesel or gasoline engine units, or open the by-pass flow regulating valve on electric powered units. Open the regulator valve for the charge pump, if applicable.
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Section 2 Operation
2. Remove the nozzles or disconnect the pump for the work to allow maximum flow to be pumped without pressure for one minute. 3. Turn on the pressurized supply line water. 4. Start the engine or the electric motor. 5. Engage the engine clutch and/or close the by-pass flow regulating valve. 6. With the nozzles removed, pump fluid through the system for at least one minute. 7. Stop the engine or motor and replace the nozzles. 8. Start the engine or motor and gradually increase flow through the system to the maximum allowable pressure. Observe the pump pressure gauge to ensure the reading does not rise above the specified allowable working pressure. If applicable, verify the charge pump pressure is at least 30 psi (1.4 bar), or 80 psi (5.5 bar) for 40,000 psi (2,758 bar) applications. 9. Set the manual and automatic throttle speed controls on the engine or adjust the by-pass flow regulating valve on electric motor driven systems to obtain the specified allowable working pressure. 10. With the pump operating at its rated full speed the maximum working pressure should be reached easily. If the maximum working pressure cannot be reached at full speed, check the nozzle size or the system plumbing for leakage. Refer to Section 10, Troubleshooting, if the issue is not resolved. 11. Ensure the suction and discharge valves remain fully open during operation.
Never close the suction or discharge valves while the pump is running.
12. Check the plunger packing for leakage.
2.5
Proper Operation
In most jetting operations is it common practice to employ a minimum of two persons as a team. The nozzle operator holds a gun, lance or delivery hose and controls the motion and direction of the jet(s). The pump operator monitors and controls the pressurizing pump during jetting operation. 1. The nozzle and pump operators should be aware of the working pressure for the job and pump and nozzle orifice sizes should be selected to match these conditions.
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Section 2 Operation
2. The pump operator should not start the unit until told to do so by the nozzle operator. Before the bringing the system up to pressure, the pump operator should ensure the jetting nozzle is either directed at the work piece; that the nozzle operator has a secure stance and control of the nozzle; and each team member is in the proper position to perform their task. 3. The pump operator should slowly raise the pressure of the system to allow the nozzle operator to adjust to the changing reaction force from the nozzle. Once the operating pressure has been reached, the pressure should not be further adjusted without the operators awareness. When the pressure is reduced at shutdown, the pressure should also be lowered slowly to prevent the sudden lack of force from causing the operator to lose their balance.
The reaction force experienced by the nozzle operator can suddenly change when the trigger on a gun activates a dry shutoff or dump valve. The operator should be familiar with the change in thrust at various pressures, including the working pressure for the job. The operators stance should allow them to withstand these changes.
4. Both before and after bringing the system up to pressure the pump operator should visually examine the hose and connections to the jetting gun or nozzle for leaks.
2.6
Decommissioning
All local regulations must be adhered to for recycling and decontamination before the pump is decommissioned and taken out of service for any reason.
2.7
System Storage
If the system will be idled for an extended period of time it must be prepared for storage as detailed below. 1. Drain and clean the power end. Leave the drain open to permit air circulation and prevent condensation buildup. NOTE Fluids can be evacuated from the pump by blowing compressed air through the suction manifold.
2. Coat all bearings and machined surfaces inside the crankshaft with a rust inhibiting oil. 3. Rotate the crankshaft once each month.
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Section 2 Operation
4. Read the engine maintenance manual for instructions regarding storage.
Cold Weather Storage

The following additional steps should be taken when the system is taken out of service in temperatures below freezing. 1. If compressed air is available, connect an appropriately secured compressed air line to the inlet connection on the suction manifold and evacuate fluids from the pump and associated plumbing. 2. If compressed air is not available, introduce anti-freeze into the suction line and rotate the pump to mix any fluid remaining in the system with anti-freeze. 3. Read the engine maintenance manual for instructions regarding cold weather storage.
Startup after Storage

A system that is removed from storage must be thoroughly inspected for damage before it is returned to service. Verify that all component parts are in working order.
Failure to observe the following instructions can result in equipment damage.
1. Open the covers on the power end, engine and drive train. 2. Verify the bearings are clean and in good condition. 3. Verify the plungers, valves and packing are properly installed and in good condition. 4. Verify proper tightness of bolts, nuts, studs and fluid connections. 5. Fill the power end to the proper level with clean oil of the proper viscosity. 6. Pour oil into the crosshead reservoir and work into all the bearings. 7. If applicable, fill the engine with oil as recommended in the engine manual included in the appendix. 8. Grease the power take off or u-joints. 9. Follow the startup and operations instructions in this section.
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SECTION 3 SAFETY GUIDELINES

3.1 Overview
KMT Aqua-Dyne products are sold with the understanding that the purchaser agrees to thoroughly train all operating and maintenance personnel in the correct and safe installation, operation and maintenance of waterblast equipment and to provide adequate supervision of personnel at all times. Waterblast operators must be made aware that the cleaning nozzles discharge jet can inflict serious bodily injury. Additional safety information and updates may be obtained from the Waterjet Technology Association website at www.wjta.org.
3.2
General Safety Guidelines

KMT Aqua-Dyne high pressure pump systems are designed to produce specifically related flows and pressures. Use caution when selecting nozzles and adjusting pressures to match the flow and working pressure of the specific pump model.
Never over-pressurize the system.
1. Use only products intended for high pressure waterblasting. No product should be altered without the written consent of the manufacturer. 2. Read and follow all manufacturers instructions prior to using any waterblast product. Contact the manufacturer should questions remain. 3. Inspect the condition of all components prior to use. Do not use an item in questionable condition. 4. Place barricades with warning signs or barricade tape around the work area.
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Section 3 Safety Guidelines
Operational Safety
Never direct high pressure fluid jets toward anyone or to any part of your body. 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. 1. The operator handling the cleaning device and nozzle must always have control of the water pressure. A surface cleaner operator should operate a trigger style, control gun capable of instantaneously stopping pressure to the nozzle. A tube cleaning lance operator should operate a foot gun capable of instantaneously stopping pressure to the lance. 2. Before attaching a nozzle to the control gun or tube cleaning lance operate the pump at low speed to purge dirt and debris from the system.
Dirt and debris can clog the nozzle orifice(s) and cause excessive system pressures that could lead to a lance failure.
3. With the nozzle installed, operate the pump at a low pressure to test the system. If system repairs or adjustments are necessary, stop the pump and relieve all pressure before making required repairs or adjustments. 4. With the system operating properly, increase pump pressure slowly until the operating pressure is reached and adjusted. Pressure adjustments should always be made slowly. 5. Use the minimum pressure required for cleaning. Do not exceed the operating pressure of the systems lowest pressure rated component. All equipment pressure rating markers and warning tags should left intact. 6. If equipment or system malfunction is suspected, immediately stop cleaning activities and relieve the pressure in the system before attempting any repairs. Always follow the manufacturers repair instructions. 7. Following any repairs, operate the pump at a low pressure to test the system. Bring the system up to the operating pressure slowly. 8. If the system is shutdown, even for brief periods, in freezing conditions, drain the water from all components. Prior to startup in freezing conditions, the operation of all components must be carefully checked to ensure they are not frozen and will operate properly.
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3.3
Pressure Relief Devices

A waterblast system should include both primary and secondary pressure relief protection.
Properly adjusted and maintained pressure relief devices are imperative for the protection of both the operator and the equipment against dangerous over pressurization.
For primary protection a spring load relief valve is set at 1.25 times the maximum operation pressure. A relief valve is set at 12,500 psi (862 bar) if the maximum operating pressure is 10,000 psi (689 bar). For secondary protection a rupture disc assembly containing a manufacturers approved disc with a burst rating of 1.5 times the maximum operating pressure is recommended. If a rupture disc assembly is used for primary pressure relief protection, it should contain a manufacturers approved disc with a burst rating of 1.25 times the maximum operating pressure.
Only use a rupture disc holder that will not permit the use of coins or other objects in place of discs.
Never adjust relief valves to open at more than 15 percent above the maximum working pressure of the pump.
Never adjust relief valves while the pump is operating under pressure.
1. Relief devices should never be mounted so the discharge could strike personnel. 2. Never install a shut-off valve between the pump and the relief device. 3. Set pressure must be prominently displayed on all relief devices. Never install a relief device unless its set pressure is known.
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4. The operation of relief valves and the accuracy of the set pressure should be field checked in accordance with manufacturers instructions at regular intervals, at least every 40 operating hours. 5. Do not attempt to correct a leaking relief valve by increasing spring tension. This will increase the set pressure. 6. Do not use a pressure relief valve as a combination relief and throttling device. 7. Keep relief valves dry during freezing conditions.
3.4
High Pressure Hose and Lance Assemblies

The minimum burst rating for high pressure hoses must be a minimum of 2.5 times the operating pressure. For example, when operating at 10,000 psi (689 bar), the hose must have a minimum burst rating of 25,000 psi (1,724 bar). Do not use a high pressure hose with an unknown burst rating or manufacturers operating pressure rating. Use of a safety shroud where the hose connects to the control gun is strongly recommended. Position the wrench on the wrench flats when making threaded connections. Do not position wrench on the fitting ferrule (collar). Protect the hose from contact with sharp objects, abrasive surfaces and foot or wheel traffic. Support hoses, pipes and fittings to prevent excessive sway and/or wear created by vibration or stress on the end connections. Inspect hoses for damage, wear or imperfections prior to and periodically during operation. Disconnect, drain, coil and store hoses properly after use.
Never attempt to repair or re-couple hoses in the field. High pressure hose fittings are permanently crimped and can only be properly installed with hydraulic crimping equipment.
Hoses must be removed from service if the: cover is damaged and reinforcing wires are exposed to rust and corrosion. cover is loose, has blisters or bulges. hose has been crushed or kinked.
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end fittings show evidence of damage, slippage or leakage. hose has been exposed to pressures greater than 50% of burst rating. hose is three or more years old, regardless of condition.
3.5
Control Gun and Control Device Safety

1. Prior to use, thoroughly inspect the control gun or device for smooth and proper operation. Control guns and devices should also be inspected for proper operation before each operating shift. Do not use any device that has not been inspected before your operating shift. 2. A control gun operator using a hand-held gun should position and brace their body for the guns rearward reaction force before depressing the gun trigger. The rearward reaction force is high and is usually 40 to 50 pounds of force. The operator should maintain firm, solid footing to counter the rearward reaction.
Do not use a hand-held control gun if the nozzle discharge can accidently strike the operators body. A 48-inch long discharge barrel must be used on hand-held control guns to prevent nozzle discharge from accidently striking the operators feet, legs or body.
3. The use of a safety shroud and a safety whip hose is strongly recommended for operator protection against a possible burst in the high pressure hose connected to the gun. Use of a hand grip and a shoulder stock with hand-held guns will provide greater comfort and thus increase cleaning production. 4. Fall protection should be provided when blasting on scaffolding or sloping surfaces. Do not operate a hand-held control gun while standing on slippery surfaces. 5. The control gun operator should always start blasting with a low system pressure and slowly increase blasting pressure. When operating pressure is reached depress and release the control gun trigger/pedal several times to check the guns operation before starting cleaning operation. 6. A dump type control gun should always open fully and reduce the system pressure to near zero immediately when the trigger/pedal is released. If the gun does relieve system pressure immediately or pressure does not fall below to 200 psi (14 bar) when the trigger/pedal is released, do not use the control gun. 7. The operator should never pass a control gun to another operator without first stopping the pump and water flow to the gun. Failure to do so is dangerous because of possible accidental trigger actuation.
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8. Do not use a control gun or control device that has malfunctioned or you suspect malfunctioned without having it repaired and/or thoroughly checked for proper operation by a qualified high pressure maintenance mechanic or your supervisor. 9. Do not use a control gun that does not have a trigger guard. 10. Never tie, wedge or clamp a control guns trigger in the blast position. 11. Hand-operated control guns should never be used as foot-operated devices. 12. Any hose used for transporting dump water back to the pump should have a large enough diameter and short enough length to keep potentially dangerous back pressure low. Protect the hose from traffic. 13. All electric throttle control cords should be rated for wet conditions. All cord connectors and switches should be kept out of water.
3.6
Rigid Tube Cleaning Lance Safety

Do not use a rigid lance with a burst rating less than 3.0 times the operating pressure. A rigid lance operating at 10,000 psi (689 bar) must have a minimum burst rating of 30,000 psi (2,068 bar). Do not use a rigid lance with an unknown burst or manufacturers operating pressure rating. 1. Clearance between the lance and tube must be sufficient to permit the unrestricted backflow of water and debris. With tubes containing hard deposits, this clearance should be a minimum of 1/8 inch on the diameter, or 1/16 inch per side, of the lance. With tubes containing soft, pliable deposits, this clearance should be greater. Insufficient side clearance may cause lance to blow back toward the operator. 2. Where practicable, a safety shield should be installed around the lance to prevent a lance nozzle from inadvertently being withdrawn and possibly causing injury. 3. Ensure the nozzle, lance and adapter thread sizes are compatible before installing the nozzle and adapter on the lance. Do not use a rigid lance that has damaged or missing threads. 4. When a pipe wrench is used to connect the lance, avoid deep wrench marks that may weaken the lance or lance connectors. 5. A rigid lance over 4 feet long requires two operators for support and safe operation. The operator at the tube entrance should use a foot control gun so they can instantly relieve system pressure in case of emergency. 6. When using and moving the lance support it in a manner to avoid stress and possible breakage at he inlet end connection. 7. Never ramrod the lance into tube blockage. 8. Transport and store lances in tubes or racks to avoid bending, corrosion or other damage. Damaged lances (bends, marks, etc.) should be removed from service.
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3.7
Flexible Tube Cleaning Lance Safety

The following lance accessories are strongly recommended for safer lance operation: A lance flexguard helps prevent fitting failure on the inlet end of the lance. A lance stinger provides greater control of the nozzle, establishes a safety zone so the operator knows when the nozzle is about to exit the tube and eliminates the possibility of nozzle and lance double back toward the operator in large diameter pipe. A safety grip prevents the lance from exiting the tube unexpectedly.
Serious injury may occur if a lance with a live nozzle exits the tube.
Do not use a flex lance with a burst rating less than 2.5 times the operating pressure. A rigid lance operating at 10,000 psi (689 bar) must have a minimum burst rating of 25,000 psi (1,724 bar). Do not use a flex lance with an unknown burst or manufacturers operating pressure rating. 1. Do not use a flex lance that is kinked, worn, frayed or when its ability to hold pressure is questionable. 2. Do not use a flex lance with damaged or missing threads. 3. Clearance between the lance and tube must be sufficient to permit the unrestricted backflow of water and debris. With tubes containing hard deposits this clearance should be a minimum of 1/8 inch on the diameter, or 1/16 inch per side, of the lance. With tubes containing soft, pliable deposits this clearance should be greater. Insufficient side clearance may cause lance to blow back toward the operator. 4. Use only nozzles designed for use with flex lances. For example, a nozzle drilled with sufficient rearward orifices so nozzle pulls the lance through the tube. 5. Where the length of the nozzle and rigid coupling is less than the inside diameter of the pipe, a length of rigid pipe, not less than the diameter of the pipe being cleaned, should be fitted directly behind the nozzle, or a suitable safety shield should be provided to protect the operator. 6. If end fittings do not have wrench flats, use properly adjusted pipe wrenches to connect the nozzle onto the lance and to connect the lance to a pressure source. When installing the nozzle on the lance apply the wrench on the end fitting directly behind the end fitting thread, not on the fitting ferrule or collar. Do not clamp the lance hose in a vice when installing the nozzle. 7. Avoid rough handling, stretching or straining of the lance. 8. Never attempt to ramrod the lance into tube blockage or to repair or re-couple lances.
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9. After use, drain, coil and restore the lance properly. Ensure safety tags remain intact.
3.8
Nozzles
Do not use a nozzle with a burst rating of less than 3.0 times, or a manufacturers pressure rating of a least, the nozzles operating pressure. 1. Prior to installation make sure the nozzle has no clogged orifices. Blocked orifices can cause excessive system pressure and failure. If an orifice appears clogged or partially blocked with dirt or debris, immediately remove the nozzle from the control gun or lance and clean. 2. Use Teflon tape when connecting nozzles with male pipe (NPT) threads. Do not let the tape overlap the thread end, tape fragments may enter the water stream and clog the orifices in the nozzle. Pipe thread connections should be hand-tight plus two (2) full wrench turns. Do not tighten past two (2) turns. All pipe thread connections must have a minimum engagement of four (4) threads.
Use wrench flats when available or a properly adjusted pipe wrench for tightening nozzle. Avoid deep wrench marks that may weaken the nozzle.
3. Special nozzles requiring a thread locking pin must have the pin installed prior to use or the nozzle may unscrew from the lance while in service, causing the lance to blow back toward the operator. 4. With nozzles requiring adjustment, always read applicable instructions.
3.9
Personal Protective Equipment

Proper safety apparel should be provided to all operators. It is strongly recommended that instructions be given regarding when and how specific clothing and other types of protective devices shall be worn.
Protective equipment may not prevent injuries to operators and other workers caused by the direct impact of high pressure waterjets or from debris that may be thrown out by the impact of the jet.
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Head Protection All operators shall be issued suitable head protection which shall be worn at all times while at the worksite. Where possible, head protection should include a full-face shield. Eye Protection Eye protection shall be provided to, and worn by, all high pressure waterjet equipment operators and all visitors to waterjet operations while they are in the working area. Eye protection must be provide the protection needed and must fit properly. Eye protection shall meet appropriate ANSI requirements for that type of eye protection. Side shields to glasses and goggles should prevent liquids from getting through.
In some cases liquids may be in use that can cause eye damage. In those cases a combination visor and goggles or a full hood with shield should be used.
Hearing Protection Waterjets generate considerable noise; both in the air and under water. All operators and all visitors shall be issued and shall wear hearing protection while in the working area. Hearing protectors should be regularly inspected and properly maintained, and should comply with federal and/or state OSHA standards. All personnel, operators and others in the vicinity of waterjet equipment should be taught how to fit and properly use ear protection so that their exposure to noise does not exceed OSHA or other regulatory limits.
Body Protection Protective clothing should be waterproof and have an outer layer that repels casual rebounding water. Protective clothing should also provide some protection from the impact of rebounding debris from the jet impact point where this may be a hazard to the operator.
Waterjets can penetrate clothing, most protective suits, skin, and cause serious injury.
Everyone working around a waterjet operation should be provided with, and should wear, sufficient waterproof clothing to provide protection from the type of exposure to water and debris that the work might create. Garments should completely cover the operator, including their arms. Liquid or chemical resistant suits shall be worn when there is a reasonable chance such equipment can prevent an injury.
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Hand Protection All operators should be provided with adequate means to protect their arms and hands. This protective equipment shall be worn when there is a reasonable chance it can prevent an injury. Foot Protection All operators and workers in the vicinity of a jetting operation should be supplied with, and shall wear, waterproof boots that have been fitted with steel tor caps. A metatarsal guard should also be worn by jetting gun operators. Respiratory Protection A respiratory program shall be implemented where there is a reasonable chance it can prevent an injury.
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SECTION 4 MAINTENANCE GUIDELINES

4.1 Overview
In order to keep the equipment in optimum operating condition, routine and preventive maintenance is essential. Only trained personnel should be authorized to perform maintenance or repairs to the equipment. All manufacturers repair instructions, including tool, torque, clearance and lubrication recommendations should be followed. Do not attempt to install or use a part whose dimensions, clearances, function or use are suspect. Repaired equipment must be carefully and thoroughly tested before it is returned to service. Do not put any piece of repaired equipment in service if its performance is questionable.
Daily Inspection
The following inspection procedures should be performed each day. If problems are detected, they should be remedied before placing the equipment in service. Prior to startup, check power end and engine oil levels and inspect oils for dirt or contamination.
Do not check the oil while the pump is running.
Check all system connections to ensure they are tight and leak proof. Check suction and discharge supply line valves to ensure they are fully open. Review relevant sections of engine and drive train manuals.
As the machine is started and water pressure increases, listen for unusual sounds. Check for plunger packing leakage. Check for leakage between the barrels and suction manifold. Check the intermediate rod and main bearing oil seals for leakage. Review relevant sections of engine and drive train manuals.
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Section 4 Maintenance Guidelines
Monthly 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 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. Maintenance procedures must be followed carefully; components must be properly cleaned prior to assembly and tightened to the correct torque specifications. Degrease, wash and clean the system monthly. Drain and refill the power end every 500 hours or as often as required to maintain clean, sludge free oil of the proper viscosity. Clean the pump and engine air breathers with a non-explosive solvent. Check studs, nuts and bolts for tightness and tighten as required. Check gaskets for leaks and replace as required.
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.
4.2
High Pressure Fittings and Connections

The minimum burst rating for high pressure fittings must be a minimum of 2.5 times the system operating pressure. All fittings shall be cleaned before installing in the system. Never use a damaged or corroded fitting, or one with damaged or missing threads. Check the condition of thread connections prior to the makeup of any high pressure connection. Do not use a component with missing or damaged threads on high pressure connections. Use Teflon tape on male pipe threads (NPT) for sealing purposes. Do not let the tape overlap the pipe thread end. Tape fragments may enter the system water stream and clog nozzle orifices. Properly tighten all high pressure connections. All pipe connections must have a minimum engagement of four (4) threads. Pipe connections should be hand-tighten plus two (2) full wrenched turns. Do not tighten pipe threads past two wrenched turns. Position the wrench on the wrench flat when making threaded connections. Do not position the wrench on the fitting ferrule. If wrench flats are not available, use a properly adjusted pipe wrench to tighten fittings. Deep wrench flats weaken fittings.
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4.3
Filters and Strainers

Regular checks should be made of all fluid filters to ensure they are not blocked or damaged. Care should be taken when examining, changing or cleaning filters to ensure that no solid particles escape into the supply lines to the pump and nozzle. Solid particles can damage valves and nozzles and make the pump run poorly. All fluid filters should be checked at regular intervals, especially when the supply water is of a poor quality.
4.4
Nozzles, Holders and Lance Connections

The system should be flushed with water before installing the nozzle. Nozzles should be checked to ensure they are not blocked or damaged and that they seat properly in the holder or manifold. The condition of the threads holding the nozzle in place should be checked to ensure they are in good condition and not worn. All damage shall be repaired, or the parts replaced, before jetting begins.
4.5
Trigger and Valve Controls

Each hand-operated and foot-operated valve shall be manually checked before a unit is placed in operation to ensure it is clean and properly functioning. Valves should be periodically disassembled to examine the condition of the internal components and to replace worn parts. Valve guards should also be inspected and any defects that might interfere with the proper operation of the unit shall be corrected.
4.6
High Pressure Hoses

Hose assemblies must be visually inspected prior to each use and thoroughly tested every six (6) months or sooner, regardless of whether they were in use or not. A visual inspection should be made at periodic intervals to determine if a hose assembly is suitable for continued service. The visual inspection must include checking for loose covers, kinks, bulges or soft spots that might indicate broken or displaced reinforcement. Couplings or fittings must be closely examined and, if there is an indication of displacement of the hose from the couplings, the hose must be removed from service.
Hydrostatic Testing
A hydrostatic test should be performed at periodic intervals to determine if a hose assembly is suitable for continued service. Hose assemblies must be hydrostatically tested for one minute for 1.5 times of the recommended working pressure every six (6) months. Water is the usual test medium. During the hydrostatic test, the hose should be straight, not coiled or in a kinked position. A regular schedule for testing hose assemblies must be established and verified with formal Inspection Records maintained in a permanent and accessible file.
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Prior to hydrostatic testing the hose assembly must be depressurized and laid out straight for visual inspection. 1. Look for cuts, gouges or worn spots in the hose cover that expose the wire reinforcement. Remove hose with exposed reinforcement from service. 2. Look for bulges in the hose cover, or for sections with mashed flats or kinks. Remove hose showing any of these faults from service. 3. Inspect for hose cover blisters or loose outer cover. Remove hose showing either of these faults from service. 4. Examine the 18-inch length of hose adjacent to the coupling carefully for damage, such as kinks, soft spots, cover cracks or permanent deformation. Remove hose showing any of these faults from service. 5. If possible, inspect the inside of the hose assembly for blisters and soft or gummy spots. Remove hose showing any of these internal faults from service. 6. Check couplings for damage. Replace all damaged couplings and hydrostatically test the hose assembly before returning it to service. 7. Check couplings for worn threads. Replace all damaged couplings and hydrostatically test the hose assembly before returning it to service. 8. Inspect couplings for excessive corrosion or rust. Replace all rusted couplings and hydrostatically test the hose assembly before returning it to service.
Only trained personnel, using proper tools and procedures, should conduct the hose assembly pressure tests.
Before conducting pressure tests on hose assemblies, provisions must be made to ensure the safety of personnel performing the tests and to prevent possible damage to property.
9. Use only clean water with a maximum temperature of 80 F (27 C). Air or other compressible gas must not be used as the test medium. 10. Prior to building up water pressure entrapped air should be bled through an outlet valve while the hose is being filled.
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11. The hose being pressure tested must be restrained by placing it in a series of anchored steel straps close to each end and at approximately 10-foot (3 m) intervals along the length. If failure occurs during the test the anchored straps should not destroy the hose but can prevent a whipping action from causing other damage or injury. 12. The outlet end of the hose should be bulwarked so that a blown out fitting cannot escape. 13. Sheet metal or a heavy matting shroud must be placed over the hose end to protect testing personnel from flying objects should a hose and bulwark failure occur during testing. 14. Test personnel must never stand in front of or to the rear of the hose ends during testing.
Proper Hose Storage

Hose assemblies in storage can be affected adversely by temperature, humidity, ozone, sunlight, oils, solvents, corrosive liquids and fumes, insects, rodents and radioactive materials. The appropriate method for storing hose depends largely on the diameter and length, the quantity to be stored and the way it is packaged. Hose should not be piled or stacked to the extent that the weight of the stack creates distortions on the lengths at the bottom. Hoses with a very thin wall will not support as much load as hoses with a heavier wall or wire reinforcement. Hose that is shipped in coils or bales should be stored so the coils lie flat on a horizontal plane. Hose assemblies should be stored in a container. Containers can provide protection against the deteriorating effects of oils, solvents and corrosive liquids. Containers also give some protection against ozone and sunlight. Rodents and insects can damage rubber hose products. Protection from them must be considered. The ideal temperature for storing hose assemblies ranges from 35 to 80 F (2 to 27 C) with a maximum limit of 100 F (38 C). If stored below 32 F (0 C) some hose will become stiff and will required warming before being placed in service. Hose assemblies should not be stored near sources of heat, such as radiators or space heaters.
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SECTION 5 POWER END ASSEMBLY
61145285 1-2013/Rev 02
5-1
INTRODUCTION
This manual describes the instructions for Repairing Series 50 pumps, and must be carefully read and understood before performing any repair intervention on the pump. Correct use and adequate maintenance is fundamental for the pumps regular operation and long wear. General Pump declines any responsibility for damage caused by the misuse or the non-observance of the instructions described in this manual.
REPAIR INSTRUCTIONS
Crank Mechanism Repair Crank mechanism repair operations must be carried out after draining the oil from the crankcase. To drain the oil, remove the oil dipstick, 1, Fig. 1, and then the draining plug (2, fig. 1).
Exhausted oil must be collected in an appropriate receptacle and disposed of in designated locations. In absolutely no case may it be disposed of in the environment.
4-15-2 56555
Crank Mechanism Disassembly The correct sequence is the following A) Drain oil and then remove: pump shaft key connecting rod cap side covers using 3 wholly threaded M6 x 50 screws, inserting them in the opposite holes as shown in fig. 2
B)
Push the plunger guides and connecting rods forward in order to facilitate the lateral extraction of the pump shaft. Two marks are visible on the crankshaft, as shown in fig. 3; they must be turned towards the operator in order to facilitate extraction. NOTE: to extract the plunger guide it is necessary to remove the ceramic plunger and wiper first.
C)
Disassemble the crankshaft oil seals and the plunger guides using standard tools.
5-3 5-3
4-18
Crank Mechanism Assembly After cleaning the crankcase, reassemble the crankcase mechanism as follows: A) Thoroughly fit the plunger guide seals into their seat on the crankcase as shown in fig. 5a, using the appropriate tool (p/n 27904900). B) Introduce the pre-assembled plunger guide/connecting rod units into their seats; to facilitate tightening of the connecting rod cap, we advise to position the connecting rod so you can easily read the number. To easily introduce the crankshaft, without the key, fully push the plunger guide/connecting rod unit, as indicated and as shown in fig. 4.
C)
Before assembly of the side covers, check the seal lips for wear. If replacement is necessary, position the new ring using the appropriate tool (p/n 27904800) as shown in fig. 5.
If the shaft presents diameter wear corresponding to the sealing lip, to avoid the need for grinding its possible to position the ring as indicated in fig. 5.
5-4
4-19
Before assembling the cover (sight glass side), be sure that the shim rings have been inserted. To help the covers fit onto the crankcase, we advise to use 3 screws M6 x 40, and then finish the operation with the screws supplied (M6 x 18) as shown in fig. 6.
D)
Install the connecting rod cap respecting numbering, and fasten the relevant bolts (lubricating both the head and the threaded stem with the same oil used for the crankcase) proceeding in three different steps. see fig. 7: 1. Approaching torque 4.3-7 Ft. Lbs. (6-8 Nm) 2. Pre fastening torque 18.4-21 Ft. Lbs. (25-28 Nm) 3. Fastening torque 28 Ft. Lbs. (38 Nm)
E) F)
Install the rear cover positioning the oil dipstick hole upward. Fill the crankcase with oil as indicated on page 4-22.
Disassembly / Assembly of Bearings and Shims The type of bearings used (tapered roller bearings), ensures the absence of axial play on the crankshaft; the shims are to be determined to reach this purpose. To assemble / disassemble, or to replace them if needed, carefully follow the indications below:
5-5
4-20
A) Assembly / Disassembly of the crankshaft without replacing the bearings After removing the side covers, as indicated in Crank Mechanism Assembly, check the rollers and their races for wear; if all parts are in good condition, fully clean the components with a suitable degreaser and grease them again evenly using the same oil in the crankcase. The same shims can be used again, being careful to fit them under the cover on the site glass side. After installing the complete unit (sight glass side flange and engine side flange), check that the shafts rolling torque - with the connecting rods free - is at least 3 Ft. Lbs. (4 Nm), Max 5 Ft. Lbs. (7 Nm). To position the two side covers on the crankcase, initially use 3 M6 x 40 screws as shown in fig. 6, and then the fastening screws. The shafts rolling torque (with connecting rods coupled must not exceed 6 Ft. Lbs. (8 Nm). B) Disassembly / Assembly of the Crankshaft With Bearings Replacement After disassembling the side covers as indicated in Crank Mechanism Assembly, remove the outer ring nut of the bearings from their covers and the inner ring nut, with the remaining part of the bearing, from the two shaft extremities using a standard pin extractor or similar tool as indicated in figures 8 and 9.
The new roller bearing can be mounted at room temperature with press; it is necessary to lay them on the lateral side of the relevant ring nuts with opposite rings. The driving operation can be facilitated by heating the relevant parts to a temperature ranging between 2500 - 3000 F, (1200 - 1500 C), making sure that the ring nuts are correctly fitted in their seats. Never invert the parts of the two bearings.
5-6 4-21
The shim pack must be reassembled as follows: A) Insert the crankshaft in the crankcase, being sure that the P.T.O. shank comes out of the correst side. B) Fit the P.T.O. side flange to the crankcase paying great attention to the seal lip as indicated in Disassembly/Assembly of Bearings and Shims, section C. C) Position the flange on the sight glass side as indicated in Disassembly/Assembly of Bearings and Shims. D) Use a thickness gauge (see fig. 10).
to determine the shim pack as indicated in the table below: Measurement From: 0.05 to 0.010 From: 0.11 to 0.20 From: 0.21 to 0.30 From: 0.31 to 0.35 From: 0.36 to 0.45 From: 0.46 to 0.55 From: 0.56 to 0.60 From 0.61 to 0.70 Shim Type 0.1 0.1 0.25 0.35 0.35 0.10 0.25 0.35 0.25 No. of Pieces 1 2 1 1 1 1 2 1 1
E) F)
Insert the shims under the cover on the sight glass side (see fig. 11), fixing it to the crankcase using the appropriate screws, and verifying that the stall torque is between 3-5 Ft. Lbs. ( 4-7 Nm). If the torque value is correct, connect the rods to the crankshaft; otherwise, reposition the shims again repeating the operations from point C.
5-7
4-22
Check the oil level by using the appropriate oil level dipstick with minimum and maximum value notches (1), fig. 3. Refill if needed. Correct oil level inspection is done with the pump at room temperature; oil is changed with the pump at working temperature, by removing the rear plug (2), fig 3. Oil is to be changed every 1000 hours of operation. The amount required is ~128.5 oz. (3.8 liters).
In any case, oil must be changed at least once a year since it may deteriorate by oxidation. For room temperatures that differ from that mentioned earlier, follow the indications contained in the diagram below, keeping in mind that the oil must have a minimum viscosity of 180 cSt. Recommended Lubricant Oil Types & Manufacturers The pump is delivered with lubricant oil, compliant with room temperatures ranging between 00 and 300C (320 and 89.60 F). Some recommended lubricant types are indicated in the table below; these lubricants are treated additives in order to increase corrosion protection and resistance to fatigue. As an alternative, Automotive SAE 85W-90 gearing lubricants may also be used. BRAND GENERAL PUMP ARAL BP CASTROL ELF ESSO FINA FUCHS MOBIL SHELL TEXACO TOTAL TYPE SERIES 220 Aral Degol BG220 ENERGOL HLP 220 Hyspin VG 220, Magna 220 POLYTELIS 220 NUTO 220 Cirkan 220 RENOLIN 220 DTE OIL BB TELLUS C 220 RANDO HD 220 CORTIS 220 VISCOSITY/ROOM TEMPERATURE DIAGRAM
Exhausted oil must be collected in an appropriate receptacle and disposed of in appropriate locations. In absolutely no case may it be dispersed into the environment.
4-23
5-8
In case of disassembly, to avoid letting dirt inside the front part of the crankcase, close the threaded hole with the appropriate cap, supplied.
Replace the crankcase cap with the oil dipstick and check oil level. The oil dipstick must always be accessible, even when the unit is assembled. The pumps shaft (PTO) must not be rigidly connected to the motor unit. The following transmission types are suggested: hydraulic by means of flange; for correct application, please contact the Customer Service Department Belts Cardan Joint (please respect the maximum working angles indicated by the manufacturer) Flexible joint 5-9
4-24
SCREW CALIBRATION
Screw calibration by means of a torque wrench only. Description Cover fastening screws Oil discharge plug Lifting bracket fastening screw Conrod caps fastening screw Plunger fastening Choke Support fastening screw Head fastening screw Liner fastening screw Hydraulic motor flange screw Exploded View Position (From Owners Manual) 19 11 17 18 28 31 44 56 57 59 Fastening Torque (Ft. Lbs.) 7.4 29.5 73.8 28 14.8 7.4 11 59 25.8 29.5 Fastening Torque (Nm) 10 40 100 38* 20 10 15**** 80** 35*** 40
* The conrod caps fastening screws must be tighteded respecting the phases indicated in Point D of page 4-19 ****The support fastening screws must be tightened in a single step
Screw 44 and 57 of the exploded view, should be greased before being tightened by means of a torque wrench.
5-10
4-25
MAINTENANCE LOG
HOURS & DATE
OIL CHANGE
GREASE
PACKING REPLACEMENT
PLUNGER REPLACEMENT
VALVE REPLACEMENT
GP Companies, Inc. 1174 Northland Drive Mendota Heights, MN 55120 Phone:651.686.2199 Fax: 800.535.1745 www.generalpump.com email: sales@gpcompanies.com
Ref 300683 Rev.A 08-09
4-26 5-11
EXPLODED VIEW AND PARTS LIST
4-27 5-12
Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Part # F71010000 91859000 90391800 F71220581 F71220381 F71220081 90075600 70211801 F90387700 F71150122 99186700 F90384100 F98218300 98212000 F71160022 F90400000 98206000 F71223074 F99512000 F99313800 F71020035 F91500000 F71150022 90170000 71030043 F97743000 F90060600 71050015 96714000 F71040802 F71040702 90167800 F96416000 F71223566 96710000
Description Pump Crankcase Roller Bearing O-ring, 94.92 x 2.62 Shim, .35 mm Shim, .25 mm Shim, .1 mm Ring, 45 Oil Level Indicator O-ring, 39.34 x 2.62 Oil Level Indicator, Side Bearing Cover Screw, M6 x 18 O-ring, 17.13 x 2.62 Plug, G 1/2 x 13 Dipstick Crankcase Cover O-ring, 215 x 3 Plug for 15 Port Lifting Eye Bolt Screw, M16 x 1.5 x 25 Connecting Rod Screw, M8 x 48 Crankshaft Crankshaft Key Motor Side Bearing Cover Ring, 50 x 65 x 8 Connecting Rod Pin, 20 x 38 Seal, 20 Plunger Guide Wiper, 10 x 50 x 1 Plunger, 14 Plunger, 12 Seal, 38 x 52 x 7 Connector, 90 degree, G 1/4 M Connector, 2.5 1/8 M-1/4 F Wiper, 10 x 14 x 1.5
QTY. 1 2 2 * * * 1 1 1 1 20 1 1 1 1 1 6 1 1 6 1 1 1 1 3 3 6 3 3 3 3 3 1 1 1
Item 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 59 60
Part # F71165020 F90366300 90389100 F90067200 F71216866 F71216766 F90260400 F90258800 F71214866 F71214766 F71211470 F71211370 F71224668 F71224368 F71060066 F90370200 F99194400 90386100 F90260600 F90259000 F71211782 F71211682 F94751800 F36205366 F93186500 F36205266 F36205166 F36205666 F94742300 F36205570 F71127056 F99455000 F99326100 99309900 F10067720
Description Spacer O-ring, 4 x 2 O-ring, 52.07 x 2.62 Seal, 30 Packing Ring, VF14 Packing Ring, VF12 L.P. Packing, VF14 L.P. Packing, VF12 Packing Support, VF14 Packing Support, VF12 Gasket, VF14 Gasket, VF12 Anti-extrusion Ring, VF14 Anti-extrusion Ring, VF12 Sleeve O-ring, 38 x 2 Screw M6 x 40 O-ring, 26.65 x 2.62 H.P. Packing, VF14 H.P. Packing, VF12 Plunger Gasket, VF14 Plunger Gasket, VF12 Spring, 21.6 x 37 Valve Plate Gasket, 24 x 29 x 3.8 Plunger Valve Seat, VF14 Plunger Valve Seat, VF12 Valve Spring, 13.9 x 23 Valve Guide Manifold Screw, M12 x 60 Screw, M8 x 100 Screw, M8 x 35 Motor Flange-Optional
QTY. 1 1 6 3 3 3 3 3 3 3 3 3 3 3 3 3 30 3 3 3 3 3 3 3 6 3 3 3 3 3 1 8 24 6 1
REPAIR KITS Item 34, 35, 38, 40, 41, 43, 45, 46 50 3, 7, 10, 14, 22, 29, 34, 35, 38 40, 41, 43, 45, 46, 50 VF12 F2037 F2038 F2036 F2039 VF14 F2035
5-13 4-28
SECTION 6 FLUID END ASSEMBLY

6.1 Maintenance Overview
Never perform any type of maintenance on the fluid end assembly while it is pressurized. Always turn the power off and bleed the high pressure water before servicing.
Figure 6-1: Fluid End Assembly
Improper assembly can lead to the premature failure of components. Maintenance procedures must be followed carefully; components must be properly cleaned prior to assembly and tightened to the correct torque specifications. NOTE Refer to Section 9, Parts List for a complete listing of replacement parts and part numbers.
61145293HP 1-2013/Rev 0
6-1
Section 6 Fluid End Assembly
Torque Specifications
Table 6-1, Torque Specifications, details the torque specifications and tightening sequences for the fluid end components and connections. Table 6-1 Torque Specifications Fluid End Assembly
Manifold Cap Screws Torque 6 (8) each 160 ft-lbs (217 Nm) Lubricated Crossing Pattern 6-Bolt Crossing Pattern
Transfer Block Cap Screws Torque 8 (45MM) each 62 ft-lbs (84 Nm) Lubricated Crossing Pattern 8-Bolt Crossing Pattern
Plunger Assembly Torque 10 ft-lbs (14 Nm) Lubricated
61145293HP 1-2013/Rev 0
6-2
6.2
Valve Assemblies
The fluid end valves are spring loaded, flat disc and seat type. Both the discharge and suction valves and seat can be removed from the front of the fluid end. Valves and seating surfaces encounter high wear during operation. Frequent inspection, maintenance and/or replacement are required to ensure proper operation. Poor suction and water quality can reduce valve life and result in rapid mechanical wear of the power end components. Valve springs should be replaced after 2,000 hours of operation to reduce the possibility of a fatigue break; or when the coils have flat wear spots due to rubbing during normal operation. The valve seat provides a seating surface for both the discharge and suction valve. Valve seat surfaces are flat and can be restored by surface grinding flat to within one to two light bands. Mating surfaces of the valve seat and the valves must be smooth and free from nicks and scratches.
Severe injury can result if the machine is not properly locked out. Observe electrical Lock Out/Tag Out procedures before performing maintenance on the system components. Ensure all pressure is relieved or blocked from the high pressure circuit before performing maintenance.
1. Disconnect all piping to the manifold. 2. Remove the cap screws attaching the manifold to the transfer block. Use a flat screwdriver or other suitable tool to pry the manifold from each barrel, leaving the barrels in position. 3. Lift the manifold off, separating it from the barrels. Place the manifold on a solid horizontal surface with the valve seats facing up.
61145293HP 1-2013/Rev 0
6-3
Figure 6-2: Valve Removal
4. Place a rod through the center bore of the valve seats and pry the seats from the manifold. Remove the discharge valves, valve springs and discharge valve guides from the manifold. 5. Remove the suction valves, valve springs and spring spacers from the barrels by sliding them out the front.
Figure 6-3: Discharge Valve Installation
61145293HP 1-2013/Rev 0
6-4
6. Install the compression seal in the counter-bore in the manifold with the radius facing up. 7. Install the discharge valve guides in the manifold, followed by the discharge valve springs and discharge valves. 8. Clean the holes in the valve seats and position the valve seats in the manifold ensuring all of the holes are facing the correct direction. 9. Use a brass rod to tap the valve seat into the manifold. One swift strike should be sufficient. Repeat for the remaining valve seats.
Do not damage the smooth sealing surface of the valve seats.
10. Install the compression seal in the face of the barrels. 11. Install the spring spacers, suction valve springs and suction valves in the barrels. 12. Apply a thin layer of FML-2 grease to the o-rings on the end of the barrels. Lift the manifold and position it onto the barrels. 13. Apply Loctite 76764 anti-seize or equivalent to the threads on the cap screws and install the screws. Torque the screws to the specifications in Table 6-1, Torque Specifications. 14. Rotate the crankshaft at least three revolutions to ensure no parts are binding.
6.3
Barrel Assemblies
1. Disconnect all piping to the manifold. 2. Remove the cap screws attaching the manifold to the transfer block. Use a flat screwdriver or other suitable tool to pry the manifold from each barrel, leaving the barrels in position. 3. Lift the manifold off, separating it from the barrels. The valve seats may or may not remain in the manifold. If not, remove the valve seats from the barrels.
61145293HP 1-2013/Rev 0
6-5
Figure 6-4: Barrel Assembly
4. Grasp the barrel firmly and pull it from the power end. Remove the remaining barrels in the same manner.
Use caution to not break the plungers when removing the barrels.
5. Apply FML-2 grease to the o-rings and insert them into the appropriate grooves on the barrel. Apply a light coat of Loctite 76764 anti-seize or equivalent to the transfer block bores. 6. Carefully push the barrel into the transfer block. Use two spring spacers to apply pressure to the packing as the barrel is being pushed into the block. This prevents the packing from separating when it goes over the plunger. 7. Align the notch in the barrel with the top of the pump. 8. Install the remaining barrels in the same manner. 6. Position the manifold onto the barrels. 7. Apply Loctite 76764 anti-seize or equivalent to the threads on the cap screws and install the screws. Torque the screws to the specifications in Table 6-1, Torque Specifications. 8. Rotate the crankshaft at least three revolutions to ensure no parts are binding.
61145293HP 1-2013/Rev 0
6-6
6.4
Packing Assemblies
Before the packing assembly can be removed for service, the barrels must be removed from the power end. Follow the procedure, Barrel Assemblies, and then proceed with Step 1 below.
1. Remove suction valve, compression spring and spring spacer from the barrel. 2. Use a wooden dowel or brass bar to press the packing seat and the rear and front packing out of the barrel.
Figure 6-5: Packing Installation
3. Install the new packing seat ensuring the chamfered edge rests against the stop in the barrel. 4. Slide the rear packing and the two front packing rings into the barrel. Install the spring spacer and use it to correctly position the packing. 5. Install the compression spring and the suction valve. 6. Replace the remaining packing assemblies and install the barrels following the procedure, Barrel Assemblies.
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6-7
6.5
Low Pressure Seal Assembly

Before the low pressure seal assembly can be removed for service, the barrels must be removed from the power end. Follow the procedure, Barrel Assemblies, and then proceed with Step 1 below.
1. Remove the retaining ring securing the low pressure seal holder.
Figure 6-6: Low Pressure Seal Installation
2. Remove the holder from the barrel. 3. Remove the low pressure seal and the o-ring from the holder, being sure not to damage the seal bore in the holder. 4. Install a new low pressure seal in the seal holder, and install a new o-ring on the holder. 5. Apply a small amount of FML-2 grease to the o-ring and insert the holder into the barrel. Secure the holder in position with the retaining ring. 6. Replace the remaining low pressure seals and install the barrels following the procedure, Barrel Assemblies.
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6-8
6.6
Plungers
The following procedure is used to replace the plungers. 1. Slowly rotate the crankshaft until a wrench can be inserted onto the back of the plunger. 2. Unscrew the plunger and remove it from the pump. 3. Inspect the plunger for wear or damage and replace if necessary. 4. To replace, apply Loctite 76764 and screw the plunger into the intermediate rod in the power end and torque to the specifications in Table 6-1, Torque Specifications.
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6-9
SECTION 7 TROUBLESHOOTING
7-1 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. 2. 3. 4. 5. High pressure line pulsation High pressure fluid loss Valve wear Packing failure Plunger damage
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7-1
Section 7 Troubleshooting
7-2
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. Series 50 Troubleshooting Guide
Malfunction 1. High pressure line pulsation Indication Gauge needle fluctuates Check Packing failure Compression seal leakage Cracked valves or valve seat Air entering the suction supply line through a loose connection or a ruptured pipe Low supply line water pressure 2. High pressure fluid loss Insufficient pressure for given nozzle size Worn suction or discharge valves Worn packing 3. Valve wear Contaminated supply water Supply water quality or chemistry Filters are correctly rated Cavitation effects Cavitation due to insufficient inlet pressure Supply water quality or chemistry Filters are correctly rated Cavitation effects Cavitation due to insufficient or low supply water pressure Packing installation Cooling lines
4.
Packing failure
Contaminated supply water
Installation damage Lack of cooling water
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7-2
Section 7 Troubleshooting
Series 50 Troubleshooting Guide

Malfunction 5. Plunger damage Indication Cavitation effects Check Low supply water pressure Air entering supply water line Contaminated supply water Supply water quality or chemistry Filters are correctly rated
61145301 1-2013/Rev 02
7-3
SECTION 8 SPECIFICATIONS
8.1 Service Connections
Inlet Ports Discharge Ports Cooling Water Ports
3/4 NPT 3/8 HP 1/8 NPT
8.2
Lubrication Specifications
Series 50 pumps are splash lubricated by circulating oil or other specified lubricants in the power end. To ensure proper power end lubrication, the oil must pour freely at lowest ambient operating temperatures. Refer to Section 5, Power End Assembly, for recommended power end lubricants and maintenance intervals.
61145319HP 1-2013/Rev 0
8-1
Section 8 Specifications
8.3
Torque Specifications
Measurements are made with lubricated components and a properly calibrated torque wrench. Inconsistencies in wrench settings, lubrication and technique may not produce a leak free seal. If a leak free seal is not achieved, there is a component problem. Table 8-1 Torque Specifications Fluid End Assembly
Discharge Manifold Cap Screws Torque 6 (8) each 160 ft-lbs (217 Nm) Lubricated Crossing Pattern 6-Bolt Crossing Pattern
Transfer Block Cap Screws Torque 8 (45MM) each 62 ft-lbs (84 Nm) Lubricated Crossing Pattern 8-Bolt Crossing Pattern
Plunger Assembly Torque 10 ft-lbs (14 Nm) Lubricated
61145319HP 1-2013/Rev 0
8-2
8.4
Water Quality Guidelines

The quality of the inlet water supply is one of the most important factors affecting component life and performance. Water treatment requirements can be determined by a water analysis. 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 8-2 Water Quality Guidelines
TDS* TDS TDS Silica pH Low TDS (< 100 ppm) Moderate TDS (100-200 ppm) High TDS (> 200 ppm) High content (> 15 ppm) Considered good water quality. Customer may choose to use softening. Can be treated by softening or TDS reduction (RO or DI) Considered poor water quality. Should be treated with RO or DI. Dual string base DI
Treated water must have a value of 6 to 8
* Note: Total dissolved solids
61145319HP 1-2013/Rev 0
8-3
8.5
Nozzle Size Selector Chart

Nozzle Rating Flow (gpm)
Orifice Nozzle inch (mm) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 .008 (.207) .012 (.293) .014 (.358) .016 (.414) .018 (.463) .020 (.507) .022 (.547) .023 (.585) .024 (.621) .026 (.654) .027 (.686) .028 (.717) .029 (.746) .030 (.774) .032 (.801) .033 (.827) .034 (.853) .035 (.878) .035 (.902)
Actual Nozzle Pressure [KSI (Bar)]

4 (276) 5 (345) 6 (414) 7 (483) 8 (552) 9 (621) 10 (689) 12 (827) 15 (1034) 20 (1379) 25 (1724) 30 (2068) 35 (2413) 40 (2758) 0.100 0.200 0.300 0.400 0.500 0.600 0.700 0.800 0.900 1.000 1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 0.112 0.224 0.335 0.447 0.559 0.671 0.783 0.894 1.006 1.118 1.230 1.342 1.453 1.565 1.677 1.789 1.901 2.012 2.124 0.122 0.245 0.367 0.490 0.612 0.735 0.857 0.980 1.102 1.225 1.347 1.470 1.592 1.715 1.837 1.960 2.082 2.205 2.327 0.132 0.265 0.397 0.529 0.661 0.794 0.926 1.058 1.191 1.323 1.455 1.587 1.720 1.852 1.984 2.117 2.249 2.381 2.513 0.141 0.283 0.424 0.566 0.707 0.849 0.990 1.131 1.273 1.414 1.556 1.697 1.838 1.980 2.121 2.263 2.404 2.546 2.687 0.150 0.300 0.450 0.600 0.750 0.900 1.050 1.200 1.350 1.500 1.650 1.800 1.950 2.100 2.250 2.400 2.550 2.700 2.850 0.158 0.316 0.474 0.632 0.791 0.949 1.107 1.265 1.423 1.581 1.739 1.897 2.055 2.214 2.372 2.530 2.688 2.846 3.004 0.173 0.346 0.520 0.693 0.866 1.039 1.212 1.386 1.559 1.732 1.905 2.078 2.252 2.425 2.598 2.771 2.994 3.118 3.291 0.194 0.387 0.581 0.775 0.968 1.162 1.356 1.549 1.743 1.936 2.130 2.324 2.517 2.711 2.905 3.098 3.292 3.486 3.679 0.224 0.447 0.671 0.894 1.118 1.342 1.565 1.789 2.012 2.236 2.460 2.683 2.907 3.131 3.354 3.578 3.801 4.025 4.249 0.250 0.500 0.750 1.000 1.250 1.500 1.750 2.000 2.250 2.500 2.750 3.000 3.250 3.500 3.750 4.000 4.250 4.500 4.750 0.274 0.548 0.822 1.095 1.369 1.643 1.917 2.191 2.465 2.739 3.012 3.286 3.560 3.834 4.108 4.382 4.656 4.930 5.203 0.296 0.592 0.887 1.183 1.479 1.775 2.071 2.366 2.662 2.958 3.254 3.550 3.845 4.141 4.437 4.733 5.029 5.324 5.620 0.316 0.632 0.949 1.265 1.581 1.897 2.214 2.530 2.846 3.162 3.479 3.795 4.111 4.427 4.743 5.060 5.376 5.692 6.008
61145319HP 1-2013/Rev 0
8-4

Orifice Nozzle inch (mm) 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0 11.0 12.0 12.5 13.0 .036 (.925) .041 (1.034) .045 (1.133) .048 (1.224) .052 (1.308) .055 (1.388) .058(1.463) .060 (1.534) .063 (1.602) .066 (1.668) .068 (1.731) .071 (1.791) .073 (1.850) .075 (1.907) .077 (1.962) .079 (2.016) .081 (2.069) .085 (2.170) .089 (2.266) .091 (2.313) .093 (2.359)

4 (276) 5 (345) 6 (414) 7 (483) 8 (552) 9 (621) 10 (689) 12 (827) 15 (1034) 20 (1379) 25 (1724) 30 (2068) 35 (2413) 40 (2758) 2.000 2.500 3.000 3.500 4.000 4.500 5.000 5.500 6.000 6.500 7.000 7.500 8.000 8.500 9.000 9.500 10.000 11.000 12.000 12.500 13.000 2.236 2.795 3.354 3.913 4.472 5.031 5.590 6.149 6.708 7.267 7.826 8.385 8.944 9.503 2.449 3.062 3.674 4.287 4.899 5.511 6.124 6.736 7.348 7.961 8.573 9.186 9.798 10.410 2.646 3.307 3.969 4.630 5.292 5.953 6.614 7.276 7.937 8.599 9.260 9.922 10.583 11.244 11.906 12.567 13.229 14.552 2.828 3.536 4.243 4.950 5.657 6.364 7.071 7.778 8.485 9.192 9.900 3.000 3.750 4.500 5.250 6.000 6.750 7.500 8.250 9.000 9.750 10.500 3.162 3.953 4.743 5.534 6.325 7.115 7.906 8.696 9.487 10.277 11.068 11.859 12.649 13.440 14.230 15.021 15.811 17.393 18.974 19.764 20.555 3.464 4.330 5.196 6.062 6.928 7.794 8.660 9.526 10.392 11.258 12.124 12.990 13.856 14.722 15.589 16.455 17.321 19.053 20.785 21.651 22.517 3.873 4.841 5.809 6.778 7.746 8.714 9.682 10.651 11.619 12.587 13.555 14.524 15.492 16.460 17.428 18.397 19.365 21.301 23.238 24.206 25.174 4.472 5.590 6.708 7.826 8.944 10.062 11.180 12.298 13.416 14.534 15.653 16.771 17.889 19.007 20.125 21.243 22.361 24.597 26.833 27.951 29.069 5.000 6.250 7.500 8.750 10.000 11.250 12.500 13.750 15.000 16.250 17.500 18.750 20.000 21.250 22.500 23.750 25.000 27.500 30.000 21.250 32.500 5.477 6.847 8.216 9.585 10.954 12.324 13.693 15.062 16.432 17.801 19.170 20.540 21.909 23.278 24.648 26.017 27.386 30.125 32.863 34.233 35.602 5.916 7.395 8.874 10.353 11.832 13.311 14.790 16.269 17.748 19.227 20.706 22.185 23.664 25.143 26.622 28.101 29.580 32.539 35.497 36.976 38.455 6.325 7.906 9.487 11.068 12.649 14.230 15.811 17.393 18.974 20.555 22.136 23.717 25.298 26.879 28.461 30.042 31.623 34.785 37.947 39.529 41.110
10.607 11.250 11.314 12.000 12.021 12.750 12.728 13.500 13.435 14.250 14.142 15.000 15.556 16.500
10.062 11.023 10.621 11.635 11.180 12.247 12.298 13.472 13.416 14.697 13.975 15.309 14.534 15.922
15.875 163971 18.000 16.536 19.197 17.678 18.750 18.385 19.500
61145319HP 1-2013/Rev 0
8-5

Orifice Nozzle inch (mm) 14.0 15.0 .096 (2.448) .100 (2.533)

4 (276) 5 (345) 6 (414) 7 (483) 8 (552) 9 (621) 10 (689) 12 (827) 15 (1034) 20 (1379) 25 (1724) 30 (2068) 35 (2413) 40 (2758) 14.000 15.000 15.653 17.146 16.771 18.371 18.520 19.843 19.799 21.000 21.213 22.500 22.136 23.717 24.249 25.981 27.111 29.047 31.305 33.541 35.000 37.500 38.341 41.079 41.413 44.371 44.272 47.434
61145319HP 1-2013/Rev 0
8-6
SECTION 9 PARTS LIST

9-1 Overview
This section contains a comprehensive list of all parts and spare parts kit for Series 50 pumps. 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 Aqua-Dyne.
KMT Aqua-Dyne Inc. PO Box 231 635 West 12th Street Baxter Springs, KS 66713 USA Phone: (800) 826-9274 Fax: (620) 856-2242 Email: wj.service@kmtwaterjet.com Email: wj.parts@kmtwaterjet.com
KMT Aqua-Dyne Inc. PO Box 231 635 West 12th Street Baxter Springs, KS 66713 USA Phone: 713-864-6929 Fax: 713-864-0313 Email: sales@aqua-dyne.com
61145327 1-2013/Rev 02
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Page 1 of 2
Prod Structure w/Drawing (KMT)

KMT Waterjet - PRODUCTION
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Page:1
PARENT: 61173682 UOM: EA DRAWING #:
TRPLX UNIT-BMX 25/50,50H15K4.9GC480AOLH 61173682P Drawing Status ------------------ ------AC 61172641P 61172807P SPEC SHT 61173286P 11505-09 BOM ONLY 61173700P 61173708P SPEC SHT DOC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------Parent 61173682 TRPLX UNIT-BMX 25/50, EA 50H15K4.9GC480AOLH Rev: 0 1 61172641 ITEM 01 TRPLX UNIT-BMX 25/50, 1.0 EA yes BASE UNIT Rev: 0 1 61172807 ITEM 02 KIT-CSTR,BMX 25/50 1.0 EA yes Rev: 1 1 61143929 ITEM 03 MTR-ELEC,50HP,326T, 1.0 EA TEFC,230-460/3/60 Rev: 0 1 61173286 ITEM 04 KIT-MNTG,MTR,50HP, 1.0 EA yes BMX 25/50 Rev: 0 1 61134070 ITEM 05 FL END ASSY-SERIES 50, 1.0 EA yes HP,20KSI,.56,AQD11505-09 Rev: 6 1 61173427 ITEM 06 KIT-BELT DR,BMX 25/50, 1.0 EA yes HI SPEED,50HP Rev: 0 1 61173700 ITEM 07 KIT-ELEC,BMX 25/50,AOL, 1.0 EA 50HP,480/3/60 Rev: 0 1 61173708 ITEM 08 KIT-ACCESS,FL END, 1.0 EA yes BMX 25/50,.56MP,W/BYP Rev: 0 1 20456034 ITEM 09 DISC-RUPT,.25 ANG,INCNL, 2.0 EA 18,000PSI Rev: 0 1 61173682M ITEM 10 MAINT MNL-AQD,TRPLX 1.0 EA UNIT 61173682 Rev: 0
End of Report
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Page:1
TRPLX UNIT-BMX 25/50,BASE UNIT 61172641P Drawing Status ------------------ ------AC 61172277P 61142152P 61172435P SPEC SHT 61172443P SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT AC AC AC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------Parent 61172641 TRPLX UNIT-BMX 25/50, EA Yes BASE UNIT Rev: 0 1 61172277 ITEM 01 FR ASSY-SERIES 25/50, 1.0 EA LIFTING FORKS,STD Rev: 0 1 61142152 ITEM 02 PWR END ASSY-VF SERIES, 1.0 EA yes MOD,DRAIN Rev: 0 1 61172435 ITEM 03 BASE-PMP,SERIES 25/50, 1.0 EA ADJ,BENT,.38 Rev: 1 1 61139623 ITEM 04 FLTR HSG ASSY-LP WTR, 1.0 EA 1.0 FNPT,AQD S23117-71 Rev: 0 1 61172443 ITEM 05 STUD-ADJ,SERIES 25/50, 4.0 EA 1.0-8X5.50 Rev: 0 1 61143937 ITEM 06 SPRKT-14MM PITCH,1.46W, 1.0 EA 90 TEETH Rev: 0 1 61143963 ITEM 07 BSHG-SPLT,TPR,QD, 1.0 EA 40MM ID,F Rev: 0 1 05075734 ITEM 08 ELB-PIPE,.75X.75,F/M, 1.0 EA 90D,SST Rev: 0 1 61104612 ITEM 09 ELB-PIPE,1.0X1.0,F/M, 3.0 EA 90D,BRS,AQD S26005-03 Rev: 0 1 61172599 ITEM 10 GA-PRESS,0-100PSI, 1.0 EA .25NPT BACK CONN,PNL MNT Rev: 0 1 61127419 ITEM 11 NPL-CLS,1.0,SCH40,BRS, 1.0 EA AQD S26535-00 Rev: 0 1 61134328 ITEM 12 TEE-PIPE,1.0,F,BRS, 1.0 EA AQD S26255-02 Rev: 0 1 61134294 ITEM 13 BSHG-PIPE,1.0X.25,M/F, 1.0 EA BRS,AQD S26161-02 Rev: 0
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04/16/13 11:37:02
Page:2
TRPLX UNIT-BMX 25/50,BASE UNIT 61172641P Drawing Status ------------------ ------SPEC SHT AC SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT AC AC AC AC AC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------1 95297628 ITEM 14 SCR-CAP,HX,1/2-13X1-1/4, 4.0 EA SST 316 Rev: 0 1 95413696 ITEM 15 WSHR-LOCK,.50X.125,SST 4.0 EA no 1 10078756 ITEM 16 BARB-HOSE,.25X.25 MNPTF, 2.0 EA STR,BRS Rev: 0 1 95838314 ITEM 17 WSHR-LOCK,.25X.063,SST 6.0 EA no Rev: 0 1 95391322 ITEM 18 WSHR-FLAT,.25X.063,SST 6.0 EA no Rev: 0 1 95252193 ITEM 19 SCR-CAP,HX,1/4-20X1-1/4, 4.0 EA no SST 316 Rev: 0 1 10078152 ITEM 20 BSHG-PIPE,.75X.50,M/F, 1.0 EA BRS Rev: 2 1 49895303 ITEM 21 ADPTR-JIC/PIPE,.50X.50, 1.0 EA M/M,STR,SST Rev: 0 1 10173805 ITEM 22 ADPTR-HOSE/JIC,.50X.50, 1.0 EA no M/F,STR,BRS,SWVL Rev: 1 1 61135980 ITEM 23 ADPTR-JIC/PIPE,1.0X1.0, 1.0 EA M/M,STR,SST,S20500-23-SS Rev: 0 1 61159764 ITEM 24 ADPTR-HOSE/JIC,1.0X1.0, 1.0 EA SWVL,STR,BRS Rev: 0 1 10079713 ITEM 25 BARB-HOSE,.50X.50 MNPTF, 1.0 EA STR,BRS Rev: 3 1 61158435 ITEM 26 BARB-HOSE,1.0X1.0 NPT, 1.0 EA BRS Rev: 0 1 61172649 ITEM 27 WSHR-FLAT,1.0X.16,SST 8.0 EA Rev: 0 1 61172657 ITEM 28 NUT-JAM,1-8,SST 8.0 EA Rev: 0 1 61172675 ITEM 29 CPLG-PIPE,.25X.25,F/F, 1.0 EA BRS Rev: 0
4/16/2013
Page 3 of 4

04/16/13 11:37:02
Page:3
TRPLX UNIT-BMX 25/50,BASE UNIT 61172641P Drawing Status ------------------ ------30031-02 AC SPEC SHT SPEC SHT SPEC SHT 61172492P SPEC SHT SPEC SHT SPEC SHT SPEC SHT 61172451P SPEC SHT SPEC SHT SPEC SHT AC AC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------1 61134393 ITEM 30 DECL PKG-ELEC UNIT, 1.0 EA yes NON CE MARK,AQD 30031-02 Rev: 1 1 61141565 ITEM 31 SCR-CAP,HX,M16X1.50X40MM 4.0 EA ,GR-5,PLTD Rev: 0 1 05035100 ITEM 32 WSHR-LOCK,M16,SST 4.0 EA Rev: 0 1 49881493 ITEM 33 SCR-CAP,HX,1/4-20X2, 2.0 EA SST 316 Rev: 0 1 61172492 ITEM 34 DRAIN-LP,SERIES 25/50, 1.0 EA NYL Rev: 0 1 61126172 ITEM 35 HOSE-PUSH ON,.25,BLUE, 10.0 IN 250 PSI,AQD S20226-XX Rev: 0 1 20421272 ITEM 36 HOSE-PUSH ON,.50,BLUE, 20.0 IN 300 PSI Rev: 0 1 61159749 ITEM 37 HOSE-PUSH ON,1.0,BLUE, 25.0 IN 175 PSI Rev: 0 1 61135574 ITEM 38 FLTR ELEM-LP WTR, 2.0 EA 10 MICRON,10.0,S23117-74 Rev: 0 1 61172451 ITEM 39 BRKT-STRTR,SERIES 25/50 1.0 EA Rev: 0 1 95660957 ITEM 40 WSHR-FLAT,.38X.078,SST 4.0 EA no 1 61113035 ITEM 41 NUT-LOCK,3/8-16, 2.0 EA SST,NYL INSR,S29570-02 Rev: 0 1 95251765 ITEM 42 SCR-CAP,HX,3/8-16X3, 2.0 EA SST 316 Rev: 0
End of Report
4/16/2013
Page 1 of 3

04/18/13 14:39:32
Page:1
FL END ASSY-SERIES 50,HP,20KSI,.56,AQD11505-09 11505-09 Drawing Status ------------------ ------AC 61145600P 40045-04 SPEC SHT SPEC SHT 40101-09 SPEC SHT 40074-09 B19406-09 SPEC SHT SPEC SHT SPEC SHT A19596-09 A29025-09 AC AC AC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------Parent 61134070 FL END ASSY-SERIES 50, EA Yes HP,20KSI,.56,AQD11505-09 Rev: 6 1 61145600 ITEM 01 BLK-XFR,SERIES 50,20KSI, 1.0 EA 01/08/10 INTGRL GDE Rev: 2 1 61126932 ITEM 02 BLK-MDLR,SERIES 50, 1.0 EA 20KSI,AQD 40045-04 Rev: 1 1 61134765 ITEM 03 SCR-CAP,SKT,3/4-10X8, 6.0 EA 09/16/09 PLTD,AQD S28258-29 Rev: 1 1 61148045 ITEM 04 SCR-CAP,SKT,M12X1.75X45 8.0 EA 04/07/10 MM,18-8 SST Rev: 0 1 61127627 ITEM 06 PLGR ASSY-EK III,.56, 3.0 EA AQD 40101-09 Rev: 0 1 61135814 ITEM 07 RNG-RTNG,INT,1.25,SST, 3.0 EA 10/16/09 2 TURN,AQD S29450-77 Rev: 0 1 61127007 ITEM 08 HLDR-SEAL,LP,.56, 3.0 EA EKIII,AQD 40074-09 Rev: 1 1 61141583 ITEM 09 SEAL ASSY-LP,.56, 3.0 EA AQD B19406-09 Rev: 0 1 20413913 ITEM 10 O RNG-023,1.06X1.19X.06, 3.0 EA 10/16/09 BN-N,D-70 Rev: 0 1 20430013 ITEM 11 O RNG-032,1.88X2.0X.06, 6.0 EA 10/16/09 BN-N,D-70 Rev: 0 1 20434215 ITEM 12 O RNG-034,2.11X2.25X.07, 3.0 EA 10/16/09 BN-N,D-70 Rev: 0 1 61124949 ITEM 13 SEAT-PKG,.56X1.0, 3.0 EA AQD A19596-09 Rev: 6 1 61114033 ITEM 14 PKG-REAR,1.0X.56X.19, 3.0 EA 09/15/09 PLSTC,HP,AQD A29025-09 Rev: 3
4/18/2013
Page 2 of 3

04/18/13 14:39:32
Page:2
FL END ASSY-SERIES 50,HP,20KSI,.56,AQD11505-09 11505-09 Drawing Status ------------------ ------B29056-09 AC 40063-09 SPEC SHT 40019-00 61141955P A29012-33 A29012-34 B19405-33 B19414-24 SPEC SHT 40099-00 AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------1 61124636 ITEM 15 PKG-FRNT,1.0X.56X.19, 6.0 EA TFLN GLS,HP,B29056-09 Rev: 4 1 61134757 ITEM 16 SPCR-SPR,SERIES 50,20KSI 3.0 EA ,.56 PLGR,AQD 40063-09 Rev: 1 1 61120199 ITEM 17 SPR-CPRSN,.975X.074X1.50 3.0 EA 10/13/09 ,SST,AQD S24135-00 Rev: 0 1 61135748 ITEM 18 VLV-SUCT,SERIES 50, 3.0 EA 10/13/09 HP,20KSI,AQD 40019-00 Rev: 1 1 61141955 ITEM 19 BARL-SERIES 50,20KSI 3.0 EA 07/22/09 Rev: 2 1 61117267 ITEM 20 SEAL-CPRSN,1.00X1.25, 3.0 EA AQD A29012-33 Rev: 1 1 61117316 ITEM 21 SEAL-CPRSN,1.125ID,GA 3.0 EA 09/15/09 SER,VHP,AQD A29012-34 Rev: 1 1 61119277 ITEM 22 SEAT-VLV,SERIES 250, 3.0 EA UHP,AQD B19405-33 Rev: 5 1 61121927 ITEM 23 VLV-DISCH,SERIES 250, 3.0 EA UHP,AQD B19414-24 Rev: 8 1 61120274 ITEM 24 SPR-CPRSN,.36X.047X1.12, 3.0 EA 11/09/00 SST,AQD S24103-34 Rev: 0 1 61135756 ITEM 25 GDE-VLV,DISCH,SERIES 100 3.0 EA 10/13/09 ,40KSI,AQD 40099-00 Rev: 1
End of Report
4/18/2013
Page 1 of 3

04/18/13 14:41:33
Page:1
KIT-ACCESS,FL END,BMX 25/50,.56MP,W/BYP 61173708P Drawing Status ------------------ ------AC SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT AC AC AC AC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------Parent 61173708 KIT-ACCESS,FL END, EA Yes BMX 25/50,.56MP,W/BYP Rev: 0 1 20441750 ITEM 01 VLV ASSY-MP,2 WAY ANG, 1.0 EA .56,20KSI Rev: 1 1 49879216 ITEM 02 GLND-TBE,MP,.56,SST, 3.0 EA 20KSI Rev: 0 1 05075585 ITEM 03 SFTY HD ASSY-MP,.56, 1.0 EA 20KSI,.25 ANG DISC Rev: 0 1 61104570 ITEM 04 ELB-PIPE,.38X.38,F/M, 1.0 EA 90D,SST,AQD S26002-01 Rev: 0 1 61110056 ITEM 05 NPL-CLS,.75,SCH40,SST, 1.0 EA AQD S26620-00 Rev: 0 1 05075726 ITEM 06 TEE-PIPE,.75,F,SST 1.0 EA Rev: 0 1 61156351 ITEM 07 ELB-PIPE,.75X.75,F/M, 2.0 EA 90D,BRS Rev: 0 1 61100859 ITEM 08 ADPTR-JIC/PIPE,.75X.75, 1.0 EA M/M,STR,SST,S20500-19-SS Rev: 0 1 20423696 ITEM 09 ADPTR-HOSE/JIC,.75X.75, 1.0 EA M/F,STR,BRS,SWVL Rev: 0 1 05091129 ITEM 10 BSHG-PIPE,.75X.25,M/F, 2.0 EA BRS Rev: 0 1 10124246 ITEM 11 ADPTR-JIC/PIPE,.25X.25, 2.0 EA M/M,STR,BRS Rev: 0 1 10174605 ITEM 12 BARB-HOSE,.25X.25 FJIC, 4.0 EA SWVL,STR,BRS Rev: 0 1 10093581 ITEM 13 ELB-PIPE,.25X.25,F/M, 1.0 EA 90D,BRS 1 61135840 ITEM 14 ADPTR-JIC/PIPE,.25X.13, 2.0 EA M/M,90D,AQD S20502-02-SS Rev: 0
4/18/2013
Page 2 of 3

04/18/13 14:41:33
Page:2
PARENT: 61173708 UOM: IN DRAWING #:
KIT-ACCESS,FL END,BMX 25/50,.56MP,W/BYP 61173708P Drawing Status ------------------ ------SPEC SHT AC SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT SPEC SHT AC AC AC AC AC AC AC AC AC AC AC
Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff ------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------1 61126172 ITEM 15 HOSE-PUSH ON,.25,BLUE, 24.0 IN 250 PSI,AQD S20226-XX Rev: 0 1 05076021 ITEM 17 TBE-MP,.56X.312X4.0, 2.0 EA SST316,C/T BTH ENDS,20K Rev: 3 1 61131939 ITEM 18 CLR-TBE,MP,.56,SST, 3.0 EA 20KSI,AE,S21639-61-AE Rev: 0 1 10103265 ITEM 19 BARB-HOSE,.75X.75 MNPTF, 1.0 EA STR,BRS Rev: 0 1 61102377 ITEM 20 BSHG-PIPE,1.0X.75,M/F, 1.0 EA SST,AQD S26164-01 Rev: 0 1 61126073 ITEM 21 HOSE-PUSH ON,.75,BLUE, 20.0 IN 250 PSI,AQD S20243-XX Rev: 0 1 61105825 ITEM 22 GA-PRESS,0-20,000PSI, 1.0 EA .56MP,SST,AQD S23002-25 Rev: 0 1 20457105 ITEM 23 ADPTR ASSY-MP/PIPE, 1.0 EA .56X.50,M/F,STR,SST,15K Rev: 0 1 10113959 ITEM 24 ELB-PIPE,.50X.50,F/M, 1.0 EA 90D,SST Rev: 0 1 20412437 ITEM 25 BSHG-PIPE,.75X.50,M/F, 1.0 EA BRS/BRZ Rev: 0 1 10079713 ITEM 26 BARB-HOSE,.50X.50 MNPTF, 2.0 EA STR,BRS Rev: 3 1 20421272 ITEM 27 HOSE-PUSH ON,.50,BLUE, 25.0 IN 300 PSI Rev: 0
End of Report
4/18/2013
Material Safety Data Sheet
Revision Date: 06/25/2008 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

Product name: Loctite(R) High Strength Threadlocker 262 Product type: Anaerobic Sealant Company address: Henkel Corporation One Henkel Way Rocky Hill, Connecticut 06067
Issue date: 06/25/2008
Item No. : 37420 / IDH No. 487231 Region: United States Contact Information: Telephone: (860) 571-5100 Emergency telephone: (860) 571-5100 Internet: www.henkelna.com
2. COMPOSITION/INFORMATION ON INGREDIENTS
Hazardous components Polyglycol dimethacrylate 25852-47-5 Bisphenol A fumarate resin 39382-25-7 Saccharin 81-07-2 Cumene hydroperoxide 80-15-9 % 60-100 ACGIH TLV None OSHA PEL None OTHER None
10-30
None
None
None
1-5
None
None
None
3
1-5
None
None
1 ppm (6 mg/m ) Skin (WEEL)
3. HAZARDS IDENTIFICATION EMERGENCY OVERVIEW

HMIS: Physical state: Color: Odor: Liquid Red Mild HEALTH: FLAMMABILITY: PHYSICAL HAZARD: Personal Protection: 2* 1 1 See Section 8
WARNING:
CAUSES EYE IRRITATION. MAY CAUSE ALLERGIC SKIN REACTION. MAY CAUSE RESPIRATORY TRACT IRRITATION. MAY CAUSE SKIN IRRITATION.
Skin, Inhalation, Eyes, Respiratory system
Relevant routes of exposure: Potential Health Effects Inhalation: Skin contact: Eye contact: Ingestion: Existing conditions aggravated by exposure:
May cause respiratory tract irritation. May cause allergic skin reaction. May cause skin irritation with discomfort or rash. Contact with eyes will cause irritation. May be harmful if swallowed. Eye, skin, and respiratory disorders.
See Section 11 for additional toxicological information.
Item No. :
37420 / IDH No. 487231 1 of 4
Product name: Loctite(R) High Strength Threadlocker 262
KMT 61144666
4. FIRST AID MEASURES
Inhalation: Skin contact:
Remove to fresh air. If symptoms develop and persist, get medical attention. Wash with soap and water. Remove contaminated clothing and shoes. Wash clothing before reuse. Get medical attention if symptoms occur. Flush with copious amounts of water, preferably, lukewarm water for at least 15 minutes, holding eyelids open all the time. Get medical attention. Do not induce vomiting. Keep individual calm. Obtain medical attention.
Eye contact:
Ingestion:
5. FIRE-FIGHTING MEASURES
Flash point: Autoignition temperature: Flammable/Explosive limits-lower %: Flammable/Explosive limits-upper %: Extinguishing media: Special fire fighting procedures: Unusual fire or explosion hazards: Hazardous combustion products: Greater than 93C (200F) Not available Not available Not available If product is involved in fire extinguish with dry powder, foam or carbon dioxide. Wear self contained breathing apparatus None Thermal decomposition can lead to release of irritating gases and vapors. Oxides of carbon. Oxides of nitrogen. Tagliabue closed cup
6. ACCIDENTAL RELEASE MEASURES

Environmental precautions: Clean-up methods: Ventilate area. Prevent product from entering drains or open waters. Scrape up spilled material and place in sealed container for disposal.
7. HANDLING AND STORAGE

Handling: Avoid contact with eyes, skin and clothing. Avoid breathing vapor and mist. Wash thoroughly after handling. For safe storage, store at or below 38C (100F). Keep in a cool, well ventilated area away from heat, sparks and open flame. Keep container tightly closed until ready for use. Refer to Section 10. For information on product shelf life contact Henkel Customer Service at (800) 243-4874.
Storage:
Incompatible products:
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. Use a NIOSH approved air purifying respirator with an organic vapor cartridge if the potential to exceed established exposure limits exists. Use impermeable gloves and protective clothing as necessary to prevent skin contact. Neoprene gloves. Butyl rubber gloves. Natural rubber gloves. Safety goggles or safety glasses with side shields. See Section 2 for exposure limits.
Respiratory protection:
Skin protection:
Eye/face protection:
Item No. :
37420 / IDH No. 487231 2 of 4
KMT 61144666
9. PHYSICAL AND CHEMICAL PROPERTIES

Physical state: Color: Odor: Vapor pressure: pH: Boiling point/range: Melting point/range: Specific gravity: Vapor density: Evaporation rate: Solubility in water: Partition coefficient (n-octanol/water): VOC content: Liquid Red Mild Less than 5 mm Hg at 27C (80F) Not applicable Greater than 149C (300F) Not available 1.05 Not available Not available Slight Not available 0.0%; 0 grams/liter
10. STABILITY AND REACTIVITY

Stability: Hazardous polymerization: Hazardous decomposition products: Incompatability: Stable. Will not occur. Oxides of carbon. Oxides of sulfur. Oxides of nitrogen. Irritating organic vapors. Phenols. Iron. Copper. Rust. Aluminum. Zinc. Reducing agents. Strong acids and oxidizing agents. Oxygen scavengers. Strong alkalis. See "Handling and Storage" (Section 7) and "Incompatabilty" (Section 10).
Conditions to avoid:
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). Carcinogen Status Hazardous components Polyglycol dimethacrylate 25852-47-5 Bisphenol A fumarate resin 39382-25-7 Saccharin 81-07-2 Cumene hydroperoxide 80-15-9 NTP Carcinogen No No No No IARC Carcinogen No No No No OSHA Carcinogen No No No No
Literature Referenced Target Organ & Other Health Effects Hazardous components Polyglycol dimethacrylate 25852-47-5 Bisphenol A fumarate resin 39382-25-7 Saccharin 81-07-2 Cumene hydroperoxide 80-15-9 Health Effects/Target Organs Allergen, Irritant Allergen, Irritant No Target Organs Allergen, Central nervous system, Corrosive, Irritant, Mutagen
12. ECOLOGICAL INFORMATION

Ecological information: Not available
Item No. :
37420 / IDH No. 487231 3 of 4
KMT 61144666
13. DISPOSAL CONSIDERATIONS

Information provided is for unused product only. Recommended method of disposal: EPA hazardous waste number: Dispose of according to Federal, State and local governmental regulations. Not a RCRA hazardous waste.
14. TRANSPORT INFORMATION

U.S. Department of Transportation Ground (49 CFR): Proper shipping name: Unrestricted Hazard class or division: None Identification number: None Packing group: None International Air Transportation (ICAO/IATA): Proper shipping name: Unrestricted Hazard class or division: None Identification number: None Packing group: None WaterTransportation (IMO/IMDG): Proper shipping name: Hazard class or division: Identification number: Packing group: Marine pollutant:
Unrestricted None None None None
15. REGULATORY INFORMATION

United States Regulatory Information TSCA 8 (b) Inventory Status: TSCA 12 (b) Export Notification: CERCLA/SARA Section 302 EHS: CERCLA/SARA Section 311/312: CERCLA/SARA 313: All components are listed or are exempt from listing on the Toxic Substances Control Act Inventory. None. None above reporting de minimus. Immediate Health Hazard, Delayed Health Hazard 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) . No California Proposition 65 listed chemicals are known to be present.
California Proposition 65:
Canada Regulatory Information CEPA DSL/NDSL Status: WHMIS hazard class: All components are listed on or are exempt from listing on the Domestic Substances List. D.2.B
16. OTHER INFORMATION

This material safety data sheet contains changes from the previous version in sections: 8 Prepared by: Regulatory Affairs
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.
Item No. :
37420 / IDH No. 487231 4 of 4
KMT 61144666
Revision Date: 06/05/2006 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

Product name: Silver Grade Anti-Seize Lubricant Product type: Lubricant Company address: Henkel Corporation 1001 Trout Brook Crossing Rocky Hill, Connecticut 06067 Item No. : 76764 Region: United States Contact Information: Telephone: 860.571.5100 Emergency telephone: 860.571.5100 Internet: www.loctite.com
Issue date: 06/05/2006
2. COMPOSITION/INFORMATION ON INGREDIENTS
Hazardous components Distillates (petroleum), hydrotreated heavy naphthenic 64742-52-5 Graphite 7782-42-5 Calcium oxide 1305-78-8 Distillates (petroleum), hydrotreated light naphthenic 64742-53-6 Aluminum 7429-90-5 Distillates (petroleum), straight-run middle 64741-44-2 Silica, quartz 14808-60-7
% 30-60
ACGIH TLV 5 mg/m TWA (mist) 10mg/m STEL (mist)
OSHA PEL 5 mg/m TWA (mist)
OTHER None
10-30
10-30
2 mg/m TWA respirable 15 mg/m (total), 5 mg/m fraction, all forms except (respirable) graphite fibers 2 mg/m TWA 5 mg/m (TWA)
None
None
10-30
5 mg/m TWA (mist) 10mg/m STEL (mist)
5 mg/mTWA ( mist)
None
5-10
10 mg/m TWA metal dust 15 mg/m TWA (total), 5 5 mg/m TWA as Al mg/m( respirable) 5 mg/m TWA (mist) 10mg/m STEL (mist) 5 mg/m mist
None
1-5
None
0.1-1
0.05 mg/m TWA respirable fraction
0.1mg/m TWA (respirable)
None
3. HAZARDS IDENTIFICATION EMERGENCY OVERVIEW

HMIS: Physical state: Color: Odor: Paste Silver Hydrocarbon-like HEALTH: FLAMMABILITY: PHYSICAL HAZARD: Personal Protection: 1 1 1 See Section 8
WARNING:
CAUSES EYE, SKIN AND RESPIRATORY TRACT IRRITATION

Skin, Inhalation, Eyes
Relevant routes of exposure: Potential Health Effects Inhalation: Skin contact: Eye contact: Item No. : 76764
Moderate respiratory tract irritation. Moderate skin irritation. Moderate eye irritation. Product name: Silver Grade Anti-Seize Lubricant 1 of 5
KMT 61148756
Ingestion:
Ingestion may cause gastrointestinal irritation, nausea, vomiting and diarrhea. Principal hazard of ingestion is aspiration into the lungs and subsequent pneumonitis. Eye, skin, and respiratory disorders.
Existing conditions aggravated by exposure:
See Section 11 for additional toxicological information.
4. FIRST AID MEASURES
Inhalation: Skin contact: Eye contact: Ingestion:
Remove to fresh air. If discomfort persists seek medical attention. Wash with soap and water. If symptoms persist, obtain medical attention. Immediately flush eyes with plenty of water for at least 15 minutes. Get medical attention. Do not induce vomiting. Get medical attention immediately.
5. FIRE-FIGHTING MEASURES
Flash point: Autoignition temperature: Flammable/Explosive limits-lower %: Flammable/Explosive limits-upper %: Extinguishing media: Special fire fighting procedures: Unusual fire or explosion hazards: Hazardous combustion products: >93C (>200F) Not determined Not available Not available Carbon dioxide (CO2). Foam. Dry chemical. None None Oxides of carbon. Oxides of nitrogen.
6. ACCIDENTAL RELEASE MEASURES

Environmental precautions: Clean-up methods: Prevent further leakage or spillage. Remove all ignition sources. Soak up with inert absorbent. Store in a closed container until ready for disposal.
7. HANDLING AND STORAGE

Handling: Storage: Incompatible products: Keep away from heat, spark and flame. Avoid contact with skin and eyes. Keep in a cool, well ventilated area. No special restrictions on storage with other products. For information on product shelf life contact Henkel Customer Service at (800) 243-4874.
8. EXPOSURE CONTROLS / PERSONAL PROTECTION

Engineering controls: Use local ventilation if general ventilation is insufficient to maintain vapor concentration below established exposure limits. Use NIOSH approved respirator if there is potential to exceed exposure limit(s). Product name: Silver Grade Anti-Seize Lubricant 2 of 5
Respiratory protection: Item No. : 76764
KMT 61148756
Skin protection: Eye/face protection:
Neoprene or oil resistant gloves Safety goggles or safety glasses with side shields. See Section 2 for exposure limits.
9. PHYSICAL AND CHEMICAL PROPERTIES

Physical state: Color: Odor: Vapor pressure: pH: Boiling point/range: Melting point/range: Specific gravity: Vapor density: Evaporation rate: Solubility in water: Partition coefficient (n-octanol/water): VOC content: Paste Silver Hydrocarbon-like <5 mmHg @20C (68 F) Not applicable Not available Not available 1.25 Not available Not available Insoluble Not determined 12.96%; 162 grams/liter
10. STABILITY AND REACTIVITY

Stability: Hazardous polymerization: Hazardous decomposition products: Incompatability: Conditions to avoid: Stable. Will not occur. None reasonably foreseeable Strong oxidizing agents. None known.
11. TOXICOLOGICAL INFORMATION
Carcinogen Status Hazardous components Distillates (petroleum), hydrotreated heavy naphthenic 64742-52-5 Graphite 7782-42-5 Calcium oxide 1305-78-8 Distillates (petroleum), hydrotreated light naphthenic 64742-53-6 Aluminum 7429-90-5 Distillates (petroleum), straight-run middle 64741-44-2 Silica, quartz 14808-60-7 NTP Carcinogen No IARC Carcinogen No OSHA Carcinogen No
No No No
No No No
No No No
No No
No No
No No
Known Carcinogen
Group 1
Yes
Literature Referenced Target Organ & Other Health Effects
Item No. :
76764 3 of 5
Product name: Silver Grade Anti-Seize Lubricant
KMT 61148756
Hazardous components Distillates (petroleum), hydrotreated heavy naphthenic 64742-52-5 Graphite 7782-42-5 Calcium oxide 1305-78-8 Distillates (petroleum), hydrotreated light naphthenic 64742-53-6 Aluminum 7429-90-5 Distillates (petroleum), straight-run middle 64741-44-2 Silica, quartz 14808-60-7
Health Effects/Target Organs Irritant
Lung Irritant, Eyes, Corrosive Irritant
Central nervous system, Irritant, Lung Irritant
Some evidence of carcinogenicity, Lung, Immune system
12. ECOLOGICAL INFORMATION

Ecological information: Not available
13. DISPOSAL CONSIDERATIONS

Information provided is for unused product only. Recommended method of disposal: EPA hazardous waste number: Dispose of according to Federal, State and local governmental regulations. Not a RCRA hazardous waste.

U.S. Department of Transportation Ground (49 CFR): Proper shipping name: Unrestricted Hazard class or division: None Identification number: None Packing group: None International Air Transportation (ICAO/IATA): Proper shipping name: Unrestricted Hazard class or division: None Identification number: None Packing group: None WaterTransportation (IMO/IMDG): Proper shipping name: Hazard class or division: Identification number: Packing group: Marine pollutant:
Unrestricted None None None None
Item No. :
76764 4 of 5
KMT 61148756
15. REGULATORY INFORMATION

United States Regulatory Information TSCA 8 (b) Inventory Status: TSCA 12 (b) Export Notification: CERCLA/SARA Section 302 EHS: CERCLA/SARA Section 311/312: CERCLA/SARA 313: California Proposition 65: All components are listed or are exempt from listing on the Toxic Substances Control Act Inventory. None. None. Immediate Health Hazard Aluminum (CAS# 7429-90-5) (dust and fumes only). No California Proposition 65 listed chemicals are known to be present.
Canada Regulatory Information
CEPA DSL/NDSL Status: WHMIS hazard class:
All components are listed on or are exempt from listing on the Domestic Substances List. D.2.A, D.2.B
16. OTHER INFORMATION

This material safety data sheet contains changes from the previous version in sections: New information added in section(s): 2 Prepared by: C.J. Michaels, Senior Product Safety & 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.
Item No. :
76764 5 of 5
KMT 61148756
LUBRIPLATE
MATERIAL SAFETY DATA SHEET
Section 1 PRODUCT NAME OR NUMBER: LUBRIPLATE Super FML-0, FML-1, FML-2 GENERIC/CHEMICAL NAME: Petroleum Lubricating Grease Manufacturer's Name: Fiske Brothers Refining Co. Address: 1500 Oakdale Ave., Toledo, Ohio 43605 - 129 Lockwood St., Newark, NJ 07105
FORMULA: Calcium Soap, USP Mineral Oil and Additives NSF Registration Nos: 125742, 125740, 125741 Emergency Telephone Number: 1-800-255-3924 - CHEM-TEL (24 hour) Telephone Number for Information: 419-691-2491 - Toledo Office
Section 2 - Hazardous Ingredients/Identity Information Hazardous Components Non-hazardous OSHA PEL ACGIH TLV Other Limits Recommended % (optional)
Hazardous Material Identification System (HMIS): Not a Controlled Product under (WHMIS) - Canada
Health - 1,
Flammability - 1, Reactivity - 0 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): Extinguishing Media: Special Fire Fighting Procedures: Unusual Fire and Explosion Hazards: COC - 435oF Flammable Limits: LEL 0.9% UEL 7.0%
Foam, Dry Chemical, Carbon Dioxide or Water Spray (Fog) Cool exposed containers with water. Use air-supplied breathing equipment for enclosed or confined spaces. Do not store or mix with strong oxidants. Empty containers retain residue. Do not cut, drill, grind, or weld, as they may explode.
KMT 20416107
PRODUCT NAME OR NUMBER - LUBRIPLATE Super FML-0, FML-1, FML-2 Section 6 - Physical/Chemical Characteristics Boiling Point: Vapor Pressure (mm Hg.): Vapor Density (AIR = 1): Solubility in Water: Appearance and Odor: >550oF <0.01 >5 Negligible Smooth, white grease with mineral oil odor. Section 7 - Reactivity Data Stability: Unstable Stable X Incompatibility (Materials to Avoid): Conditions to Avoid: N/A Specific Gravity (H 2O = 1): Melting Point: Evaporation Rate: (Butyl Acetate = 1) 0.90 - 0.91 Semi-solid <0.01
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 Will Not Occur X Conditions to Avoid: N/A
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): Ventilation Local Exhaust: Mechanical (General) Normally not needed Used to capture fumes and vapors Special: Other: N/A N/A
Protective Gloves: Use oil-resistant gloves, if needed. Other Protective Equipment:
Eye Protection: If chance of eye contact, wear goggles.
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

KMT 20416107
Prepared by: James R. Kontak
Morlina Oil SD 100 MSDS# 61044E Version 7.1 Effective Date 01/06/2009 According to OSHA Hazard Communication Standard, 29 CFR 1910.1200
1. MATERIAL AND COMPANY IDENTIFICATION Material Name : Morlina Oil SD 100
Manufacturer/Supplier
MSDS Request
SOPUS Products PO BOX 4427 Houston, TX 77210-4427 USA 877-276-7285
Emergency Telephone Number : 877-242-7400 Spill Information : 877-504-9351 Health Information 2. COMPOSITION/INFORMATION ON INGREDIENTS
Highly refined mineral oils and additives. The highly refined mineral oil contains <3% (w/w) DMSO-extract, according to IP346. 3. HAZARDS IDENTIFICATION Emergency Overview Clear pale yellow. Liquid at room temperature. Slight hydrocarbon. Not classified as dangerous for supply or conveyance. Not classified as flammable but will burn. Not classified as dangerous for the environment.
Appearance and Odour
Health Hazards Safety Hazards Environmental Hazards Health Hazards Health Hazards Inhalation Skin Contact
: : :
: Not expected to be a health hazard when used under normal conditions. : Under normal conditions of use, this is not expected to be a primary route of exposure. : Prolonged or repeated skin contact without proper cleaning can clog the pores of the skin resulting in disorders such as oil acne/folliculitis. : May cause slight irritation to eyes. : Low toxicity if swallowed. : Used oil may contain harmful impurities. : Oil acne/folliculitis signs and symptoms may include formation of black pustules and spots on the skin of exposed areas. Ingestion may result in nausea, vomiting and/or diarrhoea. : Pre-existing medical conditions of the following organ(s) or organ system(s) may be aggravated by exposure to this material: Skin. : Not classified as dangerous for the environment. : Under normal conditions of use or in a foreseeable emergency, 1/7
Eye Contact Ingestion Other Information Signs and Symptoms
Aggravated Medical Condition Environmental Hazards Additional Information
Print Date 02/12/2009

KMT 61144673
MSDS_US
this product does not meet the definition of a hazardous chemical when evaluated according to the OSHA Hazard Communication Standard, 29 CFR 1910.1200. 4. FIRST AID MEASURES General Information Inhalation Skin Contact : : : Not expected to be a health hazard when used under normal conditions. No treatment necessary under normal conditions of use. If symptoms persist, obtain medical advice. Remove contaminated clothing. Flush exposed area with water and follow by washing with soap if available. If persistent irritation occurs, obtain medical attention. Flush eye with copious quantities of water. If persistent irritation occurs, obtain medical attention. In general no treatment is necessary unless large quantities are swallowed, however, get medical advice. Treat symptomatically.
Eye Contact Ingestion Advice to Physician 5. FIRE FIGHTING MEASURES
: : :
Clear fire area of all non-emergency personnel. Flash point Upper / lower Flammability or Explosion limits Auto ignition temperature Specific Hazards : : Typical 218 C / 424 F (COC) Typical 1 - 10 %(V)(based on mineral oil)
: :
Suitable Extinguishing Media Unsuitable Extinguishing Media Protective Equipment for Firefighters
: : :
> 320 C / 608 F Hazardous combustion products may include: A complex mixture of airborne solid and liquid particulates and gases (smoke). Carbon monoxide. Unidentified organic and inorganic compounds. Foam, water spray or fog. Dry chemical powder, carbon dioxide, sand or earth may be used for small fires only. Do not use water in a jet. Proper protective equipment including breathing apparatus must be worn when approaching a fire in a confined space.
6. ACCIDENTAL RELEASE MEASURES Avoid contact with spilled or released material. For guidance on selection of personal protective equipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information on disposal. Observe all relevant local and international regulations. Protective measures : Avoid contact with skin and eyes. Use appropriate containment to avoid environmental contamination. Prevent from spreading or entering drains, ditches or rivers by using sand, earth, or other appropriate barriers. Slippery when spilt. Avoid accidents, clean up immediately. Prevent from spreading by making a barrier with sand, earth or other containment material. Reclaim liquid directly or in an 2/7 Print Date 02/12/2009
KMT 61144673
Clean Up Methods
MSDS_US
Additional Advice
absorbent. Soak up residue with an absorbent such as clay, sand or other suitable material and dispose of properly. Local authorities should be advised if significant spillages cannot be contained.
7. HANDLING AND STORAGE General Precautions : Use local exhaust ventilation if there is risk of inhalation of vapours, mists or aerosols. Properly dispose of any contaminated rags or cleaning materials in order to prevent fires. Use the information in this data sheet as input to a risk assessment of local circumstances to help determine appropriate controls for safe handling, storage and disposal of this material. Avoid prolonged or repeated contact with skin. Avoid inhaling vapour and/or mists. When handling product in drums, safety footwear should be worn and proper handling equipment should be used. Keep container tightly closed and in a cool, well-ventilated place. Use properly labelled and closeable containers. Storage Temperature: 0 - 50 C / 32 - 122 F For containers or container linings, use mild steel or high density polyethylene. PVC. Polyethylene containers should not be exposed to high temperatures because of possible risk of distortion.
Handling
Storage
Recommended Materials Unsuitable Materials Additional Information
: : :
8. EXPOSURE CONTROLS/PERSONAL PROTECTION Occupational Exposure Limits Material Oil mist, mineral Oil mist, mineral Source ACGIH ACGIH Type TWA(Mist.) STEL(Mist.) ppm mg/m3 5 mg/m3 10 mg/m3 Notation
Exposure Controls
Personal Protective Equipment Respiratory Protection
: :
The level of protection and types of controls necessary will vary depending upon potential exposure conditions. Select controls based on a risk assessment of local circumstances. Appropriate measures include: Adequate ventilation to control airborne concentrations. Where material is heated, sprayed or mist formed, there is greater potential for airborne concentrations to be generated. Personal protective equipment (PPE) should meet recommended national standards. Check with PPE suppliers. No respiratory protection is ordinarily required under normal conditions of use. In accordance with good industrial hygiene practices, precautions should be taken to avoid breathing of material. If engineering controls do not maintain airborne 3/7

KMT 61144673
MSDS_US
Hand Protection
Eye Protection Protective Clothing Monitoring Methods
: : :
Environmental Exposure Controls
concentrations to a level which is adequate to protect worker health, select respiratory protection equipment suitable for the specific conditions of use and meeting relevant legislation. Check with respiratory protective equipment suppliers. Where air-filtering respirators are suitable, select an appropriate combination of mask and filter. Select a filter suitable for combined particulate/organic gases and vapours [boiling point >65C(149 F)]. Where hand contact with the product may occur the use of gloves approved to relevant standards (e.g. Europe: EN374, US: F739) made from the following materials may provide suitable chemical protection: PVC, neoprene or nitrile rubber gloves. Suitability and durability of a glove is dependent on usage, e.g. frequency and duration of contact, chemical resistance of glove material, glove thickness, dexterity. Always seek advice from glove suppliers. Contaminated gloves should be replaced. Personal hygiene is a key element of effective hand care. Gloves must only be worn on clean hands. After using gloves, hands should be washed and dried thoroughly. Application of a non-perfumed moisturizer is recommended. Wear safety glasses or full face shield if splashes are likely to occur. Skin protection not ordinarily required beyond standard issue work clothes. Monitoring of the concentration of substances in the breathing zone of workers or in the general workplace may be required to confirm compliance with an OEL and adequacy of exposure controls. For some substances biological monitoring may also be appropriate. Minimise release to the environment. An environmental assessment must be made to ensure compliance with local environmental legislation.
9. PHYSICAL AND CHEMICAL PROPERTIES Appearance Odour pH Initial Boiling Point and Boiling Range Pour point Flash point Upper / lower Flammability or Explosion limits Auto-ignition temperature Vapour pressure Specific gravity Density Water solubility n-octanol/water partition coefficient (log Pow) Kinematic viscosity : : : : Clear pale yellow. Liquid at room temperature. Slight hydrocarbon. Not applicable. > 280 C / 536 F estimated value(s)
: Typical 0 C / 32 F : Typical 218 C / 424 F (COC) : Typical 1 - 10 %(V) (based on mineral oil) : : : : : : > 320 C / 608 F < 0.5 Pa at 20 C / 68 F (estimated value(s)) Typical 0.88 Typical 7.49 g/cm3 Negligible. > 6 (based on information on similar products)
: Typical 100 mm2/s at 40 C / 104 F 4/7

KMT 61144673
MSDS_US
Vapour density (air=1) Evaporation rate (nBuAc=1)
: > 1 (estimated value(s)) : Data not available
10. STABILITY AND REACTIVITY Stability Conditions to Avoid Materials to Avoid Hazardous Decomposition Products Hazardous Polymerisation Sensitivity to Mechanical Impact Sensitivity to Static Discharge Stable. Extremes of temperature and direct sunlight. Strong oxidising agents. Hazardous decomposition products are not expected to form during normal storage. : Data not available : Data not available : Data not available : : : :
11. TOXICOLOGICAL INFORMATION Basis for Assessment Acute Oral Toxicity Acute Dermal Toxicity Acute Inhalation Toxicity Skin Irritation Eye Irritation Respiratory Irritation Sensitisation Repeated Dose Toxicity Mutagenicity Carcinogenicity : : : : : : : : : : : Information given is based on data on the components and the toxicology of similar products. Expected to be of low toxicity: LD50 > 5000 mg/kg Expected to be of low toxicity: LD50 > 5000 mg/kg Not considered to be an inhalation hazard under normal conditions of use. Expected to be slightly irritating. Expected to be slightly irritating. Inhalation of vapours or mists may cause irritation. Not expected to be a skin sensitiser. Not expected to be a hazard. Not considered a mutagenic hazard. Product contains mineral oils of types shown to be noncarcinogenic in animal skin-painting studies. Highly refined mineral oils are not classified as carcinogenic by the International Agency for Research on Cancer (IARC). Other components are not known to be associated with carcinogenic effects. Not expected to be a hazard. Used oils may contain harmful impurities that have accumulated during use. The concentration of such impurities will depend on use and they may present risks to health and the environment on disposal. ALL used oil should be handled with caution and skin contact avoided as far as possible.
Reproductive and Developmental Toxicity Additional Information
: :
12. ECOLOGICAL INFORMATION Ecotoxicological data have not been determined specifically for this product. Information given is based on a knowledge of the components and the ecotoxicology of similar products. Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquatic organisms. Expected to be practically non toxic: LL/EL/IL50 > 5/7 Print Date 02/12/2009
KMT 61144673
MSDS_US
100 mg/l (to aquatic organisms) (LL/EL50 expressed as the nominal amount of product required to prepare aqueous test extract). Mineral oil is not expected to cause any chronic effects to aquatic organisms at concentrations less than 1 mg/l. Mobility : Liquid under most environmental conditions. Floats on water. If it enters soil, it will adsorb to soil particles and will not be mobile. Expected to be not readily biodegradable. Major constituents are expected to be inherently biodegradable, but the product contains components that may persist in the environment. Contains components with the potential to bioaccumulate. Product is a mixture of non-volatile components, which are not expected to be released to air in any significant quantities. Not expected to have ozone depletion potential, photochemical ozone creation potential or global warming potential.
Persistence/degradability
Bioaccumulation Other Adverse Effects
: :
13. DISPOSAL CONSIDERATIONS Material Disposal : Recover or recycle if possible. It is the responsibility of the waste generator to determine the toxicity and physical properties of the material generated to determine the proper waste classification and disposal methods in compliance with applicable regulations. Do not dispose into the environment, in drains or in water courses. Dispose in accordance with prevailing regulations, preferably to a recognised collector or contractor. The competence of the collector or contractor should be established beforehand. Disposal should be in accordance with applicable regional, national, and local laws and regulations.
Container Disposal
Local Legislation
US Department of Transportation Classification (49CFR) This material is not subject to DOT regulations under 49 CFR Parts 171-180.
IMDG This material is not classified as dangerous under IMDG regulations. IATA (Country variations may apply) This material is not classified as dangerous under IATA regulations. 15. REGULATORY INFORMATION The regulatory information is not intended to be comprehensive. Other regulations may apply to this material. Federal Regulatory Status Notification Status 6/7 Print Date 02/12/2009
KMT 61144673
MSDS_US
EINECS TSCA DSL
All components listed. All components listed. All components listed.
SARA Hazard Categories (311/312) No SARA 311/312 Hazards.
State Regulatory Status California Safe Drinking Water and Toxic Enforcement Act (Proposition 65) This product contains a chemical known to the State of California to cause cancer.
16. OTHER INFORMATION NFPA Rating (Health, Fire, Reactivity) MSDS Version Number MSDS Effective Date MSDS Revisions MSDS Regulation MSDS Distribution : : : : : : 0, 1, 0 7.1 01/06/2009 A vertical bar (|) in the left margin indicates an amendment from the previous version. The content and format of this MSDS is in accordance with the OSHA Hazard Communication Standard, 29 CFR 1910.1200. The information in this document should be made available to all who may handle the product. The information contained herein is based on our current knowledge of the underlying data and is intended to describe the product for the purpose of health, safety and environmental requirements only. No warranty or guarantee is expressed or implied regarding the accuracy of these data or the results to be obtained from the use of the product.
Disclaimer
7/7 Print Date 02/12/2009

KMT 61144673
MSDS_US

Blastmax 50 Eng

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BLASTMAX

OPERATION AND MAINTENANCE MANUAL

KMT AQUA-DYNE 2010

Title Page Notice Table of Contents Appendix

4.2 4.3 4.4 4.5 4.6

Troubleshooting ................................................................................................ 7-1 7.1 7.2

Specifications ..................................................................................................... 8-1 8.1 8.2 8.3 8.4 8.5

Parts List ............................................................................................................ 9-1 9.1

Emergency Medical Treatment

Worldwide Product Support

Terms and Conditions of Sale

2. Title and Risk of Loss

4. Delivery and Delays

KMT Aqua-Dyne, Inc. (AD 101) 10-2006

Terms and Conditions of Sale

10. Nuclear Liability

11. Governing Law

12. Export Control

KMT Aqua-Dyne, Inc. (AD 101) 10-2006

Before Starting the System

14. Check to ensure supply water is flowing to the system.

12. Check the plunger packing for leakage.

4. Read the engine maintenance manual for instructions regarding storage.

Cold Weather Storage

Startup after Storage

Failure to observe the following instructions can result in equipment damage.

SECTION 3 SAFETY GUIDELINES

General Safety Guidelines

Never over-pressurize the system.

Section 3 Safety Guidelines

Section 3 Safety Guidelines

Pressure Relief Devices

Section 3 Safety Guidelines

High Pressure Hose and Lance Assemblies

Section 3 Safety Guidelines

Control Gun and Control Device Safety

Section 3 Safety Guidelines

Rigid Tube Cleaning Lance Safety

Section 3 Safety Guidelines

Flexible Tube Cleaning Lance Safety

Section 3 Safety Guidelines

Personal Protective Equipment

Section 3 Safety Guidelines

Section 3 Safety Guidelines

SECTION 4 MAINTENANCE GUIDELINES

Do not check the oil while the pump is running.

Section 4 Maintenance Guidelines

High Pressure Fittings and Connections

Section 4 Maintenance Guidelines

Filters and Strainers

Nozzles, Holders and Lance Connections

Trigger and Valve Controls

High Pressure Hoses

Section 4 Maintenance Guidelines

Section 4 Maintenance Guidelines

Proper Hose Storage

SECTION 5 POWER END ASSEMBLY

Ref 300683 Rev.A 08-09

EXPLODED VIEW AND PARTS LIST

SECTION 6 FLUID END ASSEMBLY

Section 6 Fluid End Assembly

Plunger Assembly Torque 10 ft-lbs (14 Nm) Lubricated

Section 6 Fluid End Assembly