Blastmax 50 Eng

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MANUAL 61173682M(R03)

BLASTMAX SERIES 50

OPERATION AND MAINTENANCE MANUAL



611453421

1-2013/Rev 02

NOTICE

This document contains subject matter in which KMT Aqua-Dyne has proprietaryrights. Recipients of this document shall not duplicate, use or disclose informationcontained herein, in whole or in part, for other than the purpose for which thismanual was provided.

KMT Aqua-Dyne believes the information described in this manual to be accurateand reliable. Much care has been taken in its preparation; however, the Company

cannot accept any responsibility, financial or otherwise, for any consequencesarising 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 i

TABLE OF CONTENTS

Title Page

Notice

Table of Contents

Appendix

Section Page

1 Introduction ....................................................................................................... 1-1

1.1 Overview ................................................................................................ 1-1

1.2 Safety ..................................................................................................... 1-1Lockout/Tagout Procedure..................................................................... 1-1

Warning Labels ...................................................................................... 1-2Emergency Medical Treatment .............................................................. 1-5

1.3 Worldwide Product Support .................................................................. 1-5

1.4 Spare Parts ............................................................................................. 1-6Terms and Conditions of Sale

2 Operation ........................................................................................................... 2-1

2.1 Overview ................................................................................................ 2-1

2.2 Transporting ........................................................................................... 2-1

2.3 Before Starting the System .................................................................... 2-12.4 Startup .................................................................................................... 2-2

2.5 Proper Operation .................................................................................... 2-3

2.6 Decommissioning .................................................................................. 2-42.7 System Storage....................................................................................... 2-4

Cold Weather Storage ............................................................................ 2-5

Startup after Storage .............................................................................. 2-5

3 Safety Guidelines ............................................................................................... 3-1

3.1 Overview ................................................................................................ 3-13.2 General Safety Guidelines ..................................................................... 3-1

Operational Safety ................................................................................. 3-2

3.3 Pressure Relief Devices ......................................................................... 3-33.4 High Pressure Hose and Lance Assemblies ........................................... 3-4

3.5 Control Gun and Control Device Safety ................................................ 3-5

3.6 Rigid Tube Cleaning Lance Safety ........................................................ 3-63.7 Flexible Tube Cleaning Lance Safety .................................................... 3-7

3.8 Nozzles ................................................................................................... 3-8

3.9 Personal Protective Equipment .............................................................. 3-8



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4 Maintenance Guidelines ................................................................................... 4-1

4.1 Overview ................................................................................................ 4-1

Daily Inspection ..................................................................................... 4-1

Monthly Maintenance ............................................................................ 4-24.2 High Pressure Fittings and Connections ................................................ 4-2

4.3 Filters and Strainers ............................................................................... 4-3

4.4 Nozzles, Holders and Lance Connections ............................................. 4-34.5 Trigger and Valve Controls ................................................................... 4-3

4.6 High Pressure Hoses .............................................................................. 4-3

Hydrostatic Testing ................................................................................ 4-3Proper Hose Storage .............................................................................. 4-5

5 Power End Assembly ........................................................................................ 5-1

6 High Pressure Fluid End Assembly ................................................................. 6-1

6.1 Maintenance Overview .......................................................................... 6-1Torque Specifications ............................................................................ 6-2

6.2 Valve Assemblies................................................................................... 6-3

6.3 Barrel Assemblies .................................................................................. 6-56.4 Packing Assemblies ............................................................................... 6-7

6.5 Low Pressure Seal Assemblies .............................................................. 6-8

6.6 Plungers.................................................................................................. 6-9

7 Troubleshooting ................................................................................................ 7-1

7.1 Overview ................................................................................................ 7-1

7.2 Troubleshooting Guide .......................................................................... 7-2

8 Specifications ..................................................................................................... 8-1

8.1 Service Connections............................................................................... 8-1

8.2 Lubrication Specifications ..................................................................... 8-18.3 Torque Specifications ............................................................................ 8-2

8.4 Water Quality Guidelines ...................................................................... 8-3

8.5 Nozzle Size Selector Chart .................................................................... 8-4

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

9.1 Overview ................................................................................................ 9-1

APPENDIX

Exhibit

Material Safety Data Sheets



61145277

12-2009/Rev 0 1-1

SECTION 1

INTRODUCTION

1.1 Overview

The KMT Aqua-Dyne Series 50 triplex positive displacement, plunger pump systems aredesigned 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 alltimes.

• 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 theunexpected 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.



Section 1

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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 devicethat can be securely attached to the machine warning personnel not to operate the energy isolatingdevice. 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 machineshall 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 1-2Warning Label Precautions

1

The poser source for electric units can present anelectrical shock hazard.

Always disconnect and lockout the power source onelectric units before performing any type of maintenance

P/N 05114962



Section 1

Introduction

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12-2009/Rev 0 1-3

Table 1-2

Warning Label Precautions

2

The surface of high pressure water and pneumaticcomponents become hot during normal operation.Failed, or failing components, can become extremely

hot during operation.

P/N 05114970

3

Ensure that all protective guards, shields or covers arein place on the equipment at all times. Never operate

the pump with the guards removed.

P/N 80082209

4

High pressure water and/or air pressure can remain inthe 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

5

All personnel involved in the installation, operationand/or service of the pump must carefully read,understand and follow the procedures in this manual toavoid creating unsafe conditions, risking damage to the

equipment, or personal injury.

P/N 20415794



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Introduction

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12-2009/Rev 0 1-4

Table 1-2

Warning Label Precautions

6

Safe operation of the unit and accessories must befollowed to prevent injury.

P/N S25561-74

Safety precautions and warnings for specific procedures are emphasized throughout this manualas 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 resultin serious personal injury or death.

Cautions emphasize operating or service procedures, or conditions that can result inequipment damage or impairment of system operation.

NOTE

Notes provide additional information that can expedite or improve operating or service procedures.



Section 1

Introduction

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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, 2812Kg/cm2) with a jet velocity of 2,434 fps (742 mps).

Foreign material (sand) may have been injected with

water. Unusual infections with microaerophilicorganisms occurring at lower temperatures have been

reported, such as gram negative pathogens as arefound 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 aqualified surgeon. Circulation may be compromised,

therefore, DO NOT APPLY HEAT TO INJUREDPART. 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 questionsregarding equipment installation and service. Technical assistance is available by phone and on-site support is available on request.

On-site technical assistance is available during equipment installation and startup. Additionally,technical support for service and maintenance issues and training of operators and maintenance

personnel is available. Periodic training sessions are also conducted at KMT Aqua-Dynedesignated locations.

Contact the KMT Aqua-Dyne Customer Service Department for additional information.

USA Customer Service Department USA Customer Service Department

KMT Aqua-Dyne Inc.

PO Box 231635 West 12th Street

Baxter Springs, KS 66713USA

Phone: (800) 826-9274Fax: (620) 856-2242Email: [email protected]

Email: [email protected]

KMT Aqua-Dyne Inc.

PO Box 231635 West 12th StreetBaxter Springs, KS 66713USA

Phone: 713-864-6929

Fax: 713-864-0313Email: [email protected]



Section 1

Introduction

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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.



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

Terms and Conditions of Sale

1. GeneralThe Terms and Conditions of Sale outlined herein shall apply

to the sale by KMT Aqua-Dyne Inc. (hereinafter referred to asCompany) 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 hereinThe 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 withany 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.

2. Title and Risk of LossTitle 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, regardlessof 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 causewherein the Company shall be named as an additional insured.

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 DelaysDelivery 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 towar, 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 theevent 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 receiptof Equipment shall constitute a waiver of any claims for delay.

5. TaxesThe 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 applicableto, measured by, imposed upon or result from this transaction or

any services performed in connection therewith. Such taxes will beitemized 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 exemptioncertificate 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 theCompany is required to pay.

6. Set Offs Neither Purchaser nor any affiliated company or assignee shall

have the right to claim compensation or to set off against anyamounts which become payable to the Company under this contract

or otherwise.

7. PatentsThe 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 thatthe 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 toaccept 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.

8. WarrantyThe 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 firstoccur. 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, butmanufactured 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. Unlessresponsibility 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, ANDALL 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 outof such Equipment.



Terms and Conditions of Sale

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

The Purchaser shall not operate Equipment which is

considered to be defective, without first notifying the Company inwriting of its intention to do so. Any such use of Equipment will

be at the Purchaser's sole risk and liability.

9. Limitation of LiabilityTHE REMEDIES OF THE PURCHASER SET FORTHHEREIN ARE EXCLUSIVE, AND THE TOTAL LIABILITY OF

THE COMPANY WITH RESPECT TO THIS CONTRACT OR

THE EQUIPMENT AND SERVICES FURNISHEDHEREUNDER. 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 ANYCONSEQUENTIAL, 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 NON-

OPERATION, 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.

10. Nuclear LiabilityIn 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 Companyagainst liability and hereby releases and agrees to indemnify the

Company and its suppliers for any nuclear damage, including lossof 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.

11. Governing LawThe 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 ControlThe Company’s products are U.S. origin items and subject to

U.S. export control laws, including the Export AdministrationRegulations. 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 exportlicenses.

13. ExecutionThe 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.



61144335

11-2009/Rev 0 2-1

SECTION 2

OPERATION

2.1 Overview

Commissioning requirements and procedures are detailed in this section. These proceduresrequire a thorough understanding of the individual components, safety issues, and the overalloperation of the system.

All personnel involved in the operation and/or service of the system must carefully review thismanual 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 isalso available.

2.2 Transporting

The weight of the machine is not evenly distributed from one end to the other, particularly on thelarger horsepower models. Do not attempt to lift the machine from either end. Note the warningsstamped on the unit. The center of gravity is located at approximately the location of the liftingeye 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 manufacturer’s 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, Specificationsfor 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.



Section 2

Operation

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11-2009/Rev 0 2-2

5. Check fuel tank levels on engine powered units.

Check engine power take off and drive train for tension and lubrication, see themanufacturer’s 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 tohelp 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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Operation

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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 riseabove 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 allowableworking pressure.

10. With the pump operating at its rated full speed the maximum working pressure should bereached 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 jettingoperation.

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.



Section 2

Operation

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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 jettingnozzle 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 nozzleoperator 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

operator’s 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 operator’s 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 asdetailed 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 thesuction manifold.

2. Coat all bearings and machined surfaces inside the crankshaft with a rust inhibiting oil.

3. Rotate the crankshaft once each month.



Section 2

Operation

61144335

11-2009/Rev 0 2-5

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 intemperatures below freezing.

1. If compressed air is available, connect an appropriately secured compressed air line to theinlet 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.



61144343

11-2009/Rev 0 3-1

SECTION 3

SAFETY GUIDELINES

3.1 Overview

KMT Aqua-Dyne products are sold with the understanding that the purchaser agrees tothoroughly 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 nozzle’s discharge jet can inflictserious bodily injury.

Additional safety information and updates may be obtained from the Waterjet TechnologyAssociation website at www.wjta.org.

3.2 General Safety Guidelines

KMT Aqua-Dyne high pressure pump systems are designed to produce specifically related flowsand 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 questionablecondition.

4. Place barricades with warning signs or barricade tape around the work area.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-2

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 instantaneouslystopping pressure to the lance.

2. Before attaching a nozzle to the control gun or tube cleaning lance operate the pump atlow 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 makingrequired 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 system’s 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

manufacturer’s 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 allcomponents must be carefully checked to ensure they are not frozen and will operate

properly.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-3

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 manufacturer’s 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

manufacturer’s 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 maximumworking 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.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-4

4. The operation of relief valves and the accuracy of the set pressure should be field checked

in accordance with manufacturer’s 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 willincrease 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 manufacturer’s 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 fittingsare 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.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-5

• 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 operatingshift.

2. A control gun operator using a hand-held gun should position and brace their body for thegun’s rearward reaction force before depressing the gun trigger. The rearward reactionforce 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 accidentlystrike the operator’s body. A 48-inch long discharge barrel must be used onhand-held control guns to prevent nozzle discharge from accidently striking the

operator’s 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. Donot 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 gun’s 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 thetrigger/pedal is released, do not use the control gun.

7. The operator should never pass a control gun to another operator without first stoppingthe pump and water flow to the gun. Failure to do so is dangerous because of possible

accidental trigger actuation.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-6

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 gun’s 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 enoughdiameter 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 tubescontaining 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 lancenozzle from inadvertently being withdrawn and possibly causing injury.

3. Ensure the nozzle, lance and adapter thread sizes are compatiblebefore installing thenozzle and adapter on the lance. Do not use a rigid lance that has damaged or missingthreads.

4. When a pipe wrench is used to connect the lance, avoid deep wrench marks that mayweaken the lance or lance connectors.

5. A rigid lance over 4 feet long requires two operators for support and safe operation. Theoperator at the tube entrance should use a foot control gunso 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.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-7

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, frayedor 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 tubescontaining 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 withsufficient 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 befitted directly behind the nozzle, or a suitable safety shield should be provided to protectthe operator.

6.

If end fittings do not have wrench flats, use properly adjusted pipe wrenches to connectthe 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 fittingthread, not on the fitting ferrule or collar. Do not clamp the lance hose in a vice wheninstalling 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.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-8

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 ratingof a least, the nozzle’s 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 lanceand clean.

2. Use Teflon tape when connecting nozzles with male pipe (NPT) threads. Do not let thetape 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 engagementof 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 protectivedevices shall be worn.

Protective equipment may not prevent injuries to operators and other workerscaused by the direct impact of high pressure waterjets or from debris that may be

thrown out by the impact of the jet.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-9

• 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 protectionshall 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 acombination 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 taughthow 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 theimpact of rebounding debris from the jet impact point where this may be a hazard to theoperator.

Waterjets can penetrate clothing, most protective suits, skin, and cause seriousinjury.

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 suchequipment can prevent an injury.



Section 3

Safety Guidelines

61144343

11-2009/Rev 0 3-10

• 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 preventan 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 metatarsalguard 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.



61144351

11-2009/Rev 0 4-1

SECTION 4

MAINTENANCE GUIDELINES

4.1 Overview

In order to keep the equipment in optimum operating condition, routine and preventivemaintenance 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 lubricationrecommendations 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. Donot 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.



Section 4

Maintenance Guidelines

61144351

11-2009/Rev 0 4-2

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 willassist 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 proceduresmust 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 systemoperating 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 pressureconnections.

• 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 properlyadjusted pipe wrench to tighten fittings. Deep wrench flats weaken fittings.



Section 4


61144351

11-2009/Rev 0 4-3

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 valvesand 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 ingood 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 inoperation to ensure it is clean and properly functioning. Valves should be periodicallydisassembled 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 thatmight 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 hosemust be removed from service.

Hydrostatic Testing

A hydrostatic test should be performed at periodic intervals to determine if a hose assembly issuitable 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, notcoiled 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.



Section 4


61144351

11-2009/Rev 0 4-4

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 thesefaults from service.

4. Examine the 18-inch length of hose adjacent to the coupling carefully for damage, such askinks, 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 thehose assembly before returning it to service.

7. Check couplings for worn threads. Replace all damaged couplings and hydrostatically testthe 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 hoseassembly pressure tests.

Before conducting pressure tests on hose assemblies, provisions must be made toensure the safety of personnel performing the tests and to prevent possible damage

to property.

9. Use only clean water with a maximum temperature of 80º F (27 º 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 valvewhile the hose is being filled.



Section 4


61144351

11-2009/Rev 0 4-5

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 thelength. If failure occurs during the test the anchored straps should not destroy the hose butcan 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 quantityto be stored and the way it is packaged. Hose should not be piled or stacked to the extent that theweight 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 isshipped 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 thedeteriorating effects of oils, solvents and corrosive liquids. Containers also give some protectionagainst 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 35º to 80º F (2º to 27º C) with a

maximum limit of 100º F (38º C). If stored below 32º F (0º 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.



61145285

1-2013/Rev 025-1

SECTION 5

POWER END ASSEMBLY



4-156555

INTRODUCTIONThis manual describes the instructions for Repairing Series 50 pumps, and must be carefully read andunderstood before performing any repair intervention on the pump. Correct use and adequate maintenance isfundamental for the pump’s 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 drainthe 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 indesignated locations. In absolutely no case may it be disposed of in the environment.

5-2



4-18

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 holesas shown in fig. 2

B) Push the plunger guides and connecting rods forward in order to facilitate the lateralextraction of the pump shaft. Two marks are visible on the crankshaft, as shown in fig. 3; theymust be turned towards the operator in order to facilitate extraction. NOTE: to extract theplunger 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.

5-35-3



4-19

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 caneasily 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 it’s possible to position the ring as indicated in fig. 5.

5-4



4-20

Before assembling the cover (sight glass side), be sure that the shim rings have been inserted. To help thecovers fit onto the crankcase, we advise to use 3 screws M6 x 40, and then finish the operation with thescrews supplied (M6 x 18) as shown in fig. 6.

D) Install the connecting rod cap respecting numbering, and fasten the relevant bolts (lubricatingboth the head and the threaded stem with the same oil used for the crankcase) proceeding inthree 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) Install the rear cover positioning the oil dipstick hole upward.F) 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; theshims are to be determined to reach this purpose. To assemble / disassemble, or to replace them if needed,

carefully follow the indications below:

5-5



4-21

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 againevenly 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 engineside flange), check that the shaft’s 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 asshown 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 thebearings from their covers and the inner ring nut, with the remaining part of the bearing, from the two shaftextremities 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 thelateral 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



4-22

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:

E) Insert the shims under the cover on the sight glass side (see fig. 11), fixing it to the crankcaseusing the appropriate screws, and verifying that the stall torque is between 3-5 Ft. Lbs.( 4-7 Nm).

F) If the torque value is correct, connect the rods to the crankshaft; otherwise, reposition theshims again repeating the operations from point C.

MeasurementShim

Type

No. of

Pieces

From: 0.05 to 0.010 - -

From: 0.11 to 0.20 0.1 1

From: 0.21 to 0.30 0.1 2

From: 0.31 to 0.35 0.25 1

From: 0.36 to 0.45 0.35 1

From: 0.46 to 0.550.350.10

11

From: 0.56 to 0.60 0.25 2

From 0.61 to 0.700.35

0.25

1

1

5-7



4-23

Recommended Lubricant Oil Types & Manufacturers

The pump is delivered with lubricant oil, compliant withroom temperatures ranging between 00 and 300C (320

and 89.60 F). Some recommended lubricant types are

indicated in the table below; these lubricants are treatedadditives in order to increase corrosion protection and

resistance to fatigue. As an alternative, Automotive SAE85W-90 gearing lubricants may also be used.

BRAND TYPE

GENERAL PUMP SERIES 220

ARAL Aral Degol BG220

BP ENERGOL HLP 220

CASTROL Hyspin VG 220, Magna 220

ELF POLYTELIS 220

ESSO NUTO 220

FINA Cirkan 220

FUCHS RENOLIN 220

MOBIL DTE OIL BB

SHELL TELLUS C 220

TEXACO RANDO HD 220

TOTAL CORTIS 220

Check the oil level by using the appropriate oil level dip-stick with minimum and maximum value notches (1), fig. 3.

Refill if needed. Correct oil level inspection is done with thepump 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 men-

tioned earlier, follow the indications contained inthe diagram below, keeping in mind that the oil

must have a minimum viscosity of 180 cSt.

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.

VISCOSITY/ROOM TEMPERATURE DIAGRAM

5-8



4-24

In case of disassembly, to avoid letting dirt inside the front

part of the crankcase, close the threaded hole with theappropriate cap, supplied.

Replace the crankcase cap with the oil dipstick

and check oil level. The oil dipstick must alwaysbe accessible, even when the unit is assembled.

The pump’s 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 maximumworking angles indicated by the manufacturer)

• Flexible joint

5-9



4-25

SCREW CALIBRATION

Screw calibration by means of a torque wrench only.

Screw 44 and 57 of the exploded view, should be greased before being tightened by

means of a torque wrench.

Description Exploded View Position(From Owner’s Manual)

Fastening Torque(Ft. Lbs.)

Fastening Torque(Nm)

Cover fastening screws 19 7.4 10

Oil discharge plug 11 29.5 40

Lifting bracket fastening screw 17 73.8 100

Conrod caps fastening screw 18 28 38*

Plunger fastening 28 14.8 20

Choke 31 7.4 10

Support fastening screw 44 11 15****

Head fastening screw 56 59 80**

Liner fastening screw 57 25.8 35***Hydraulic motor flange screw 59 29.5 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

5-10



Ref 300683 Rev.A

08-09

4-26

MAINTENANCE LOG

OIL CHANGE

GREASE

PACKING

REPLACEMENT

PLUNGER

REPLACEMENT

VALVE

REPLACEMENT

HOURS & DATE

GP Companies, Inc.

1174 Northland Drive

Mendota Heights, MN 55120

Phone:651.686.2199 Fax: 800.535.1745

www.generalpump.com email: [email protected]

5-11



4-27

EXPLODED VIEW AND PARTS LIST

5-12



4-28

REPAIR KITS

Item VF12 VF14

34, 35, 38, 40, 41, 43, 45, 46 F2037 F2035

50 F2038

3, 7, 10, 14, 22, 29, 34, 35, 3840, 41, 43, 45, 46, 50

F2036 F2039

Item Part # Description QTY.

1 F71010000 Pump Crankcase 1

2 91859000 Roller Bearing 2

3 90391800 O-ring, Ø 94.92 x 2.62 2

4

F71220581 Shim, .35 mm *

F71220381 Shim, .25 mm *

F71220081 Shim, .1 mm *

5 90075600 Ring, Ø 45 1

6 70211801 Oil Level Indicator 1

7 F90387700 O-ring, Ø 39.34 x 2.62 1

8 F71150122 Oil Level Indicator, Side Bearing Cover 1

9 99186700 Screw, M6 x 18 20

10 F90384100 O-r ing, Ø 17.13 x 2.62 1

11 F98218300 Plug, G 1/2” x 13 1

12 98212000 Dipstick 1

13 F71160022 Crankcase Cover 1

14 F90400000 O-ring, Ø 215 x 3 1

15 98206000 Plug for Ø 15 Port 6

16 F71223074 Lifting Eye Bolt 1

17 F99512000 Screw, M16 x 1.5 x 25 1

18 F99313800 Connecting Rod Screw, M8 x 48 6

19 F71020035 Crankshaft 1

20 F91500000 Crankshaft Key 1

21 F71150022 Motor Side Bearing Cover 1

22 90170000 Ring, Ø50 x 65 x 8 1

23 71030043 Connecting Rod 324 F97743000 Pin, Ø 20 x 38 3

25 F90060600 Seal, Ø 20 6

26 71050015 Plunger Guide 3

27 96714000 Wiper, Ø 10 x 50 x 1 3

28F71040802 Plunger, Ø 14 3

F71040702 Plunger, Ø 12 3

29 90167800 Seal, Ø 38 x 52 x 7 3

30 F96416000 Connector, 90 degree, G 1/4” M 1

31 F71223566 Connector, Ø 2.5 1/8” M-1/4” F 1

32 96710000 Wiper, Ø 10 x 14 x 1.5 1

Item Part # Description QTY.

33 F71165020 Spacer 1

34 F90366300 O-ring, Ø 4 x 2 1

35 90389100 O-ring, Ø 52.07 x 2.62 6

36 F90067200 Seal, Ø 30 3

37F71216866 Packing Ring, VF14 3

F71216766 Packing Ring, VF12 3

38F90260400 L.P. Packing, VF14 3

F90258800 L.P. Packing, VF12 3

39F71214866 Packing Support, VF14 3

F71214766 Packing Support, VF12 3

40F71211470 Gasket, VF14 3

F71211370 Gasket, VF12 3

41F71224668 Anti-extrusion Ring, VF14 3

F71224368 Anti-extrusion Ring, VF12 3

42 F71060066 Sleeve 3

43 F90370200 O-ring, Ø 38 x 2 3

44 F99194400 Screw M6 x 40 30

45 90386100 O-ring, Ø 26.65 x 2.62 3

46F90260600 H.P. Packing, VF14 3

F90259000 H.P. Packing, VF12 3

47F71211782 Plunger Gasket, VF14 3

F71211682 Plunger Gasket, VF12 3

48 F94751800 Spring, Ø 21.6 x 37 3

49 F36205366 Valve Plate 3

50 F93186500 Gasket, Ø 24 x 29 x 3.8 6

51F36205266 Plunger Valve Seat, VF14 3

F36205166 Plunger Valve Seat, VF12 3

52 F36205666 Valve 3

53 F94742300 Spring, Ø 13.9 x 23 3

54 F36205570 Valve Guide 3

55 F71127056 Manifold 1

56 F99455000 Screw, M12 x 60 8

57 F99326100 Screw, M8 x 100 24

59 99309900 Screw, M8 x 35 6

60 F10067720 Motor Flange-Optional 1

5-13



61145293HP

1-2013/Rev 0 6-1

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 partnumbers.



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-2

Torque Specifications

Table 6-1, Torque Specifications, details the torque specifications and tightening sequences for

the fluid end components and connections.

Table 6-1


Fluid End Assembly

Manifold

Cap Screws 6 (8”) each

Torque 160 ft-lbs (217 Nm) Lubricated

Crossing Pattern

6-Bolt Crossing Pattern

Transfer Block

Cap Screws 8 (45MM) each


Crossing Pattern


Plunger Assembly




Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-3

6.2 Valve Assemblies

The fluid end valves are spring loaded, flat disc and seat type. Both the discharge and suctionvalves 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 possibilityof a fatigue break; or when the coils have flat wear spots due to rubbing during normaloperation.

• 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. Observeelectrical 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 barrelsin 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.



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-4

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 slidingthem out the front.

Figure 6-3: Discharge Valve Installation



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-5

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 springsand discharge valves.

8. Clean the holes in the valve seats and position the valve seats in the manifold ensuring allof the holes are facing the correct direction.

9. Use a brass rod to tap the valve seat into the manifold. One swift strike should besufficient. 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


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 flatscrewdriver or other suitable tool to pry the manifold from each barrel, leaving the barrelsin 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.



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-6

Figure 6-4: Barrel Assembly

4. Grasp the barrel firmly and pull it from the power end. Remove the remaining barrels inthe 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 pressureto 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 installthe 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.



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-7

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.


system components.

Ensure all pressure is relieved or blocked from the high pressure circuit before performing maintenance.

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 springspacer 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.



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-8

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.

Severe injury can result if the machine is not properly locked out. Observe

electrical Lock Out/Tag Out procedures before performing maintenance on thesystem components.

Ensure all pressure is relieved or blocked from the high pressure circuit before

performing maintenance.

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 theseal 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.



Section 6

Fluid End Assembly

61145293HP

1-2013/Rev 0 6-9

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.



61145301

1-2013/Rev 02 7-1

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. High pressure line pulsation

2. High pressure fluid loss

3. Valve wear

4. Packing failure

5. Plunger damage



Section 7

Troubleshooting

61145301

1-2013/Rev 02 7-2

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 Departmentfor assistance.

Series 50 Troubleshooting Guide

Malfunction Indication Check

1. High pressure line pulsation Gauge needle fluctuates 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

4. Packing failure Contaminated supply water Supply water quality or

chemistry


Cavitation effects Cavitation due to insufficient or

low supply water pressure

Installation damage Packing installation

Lack of cooling water Cooling lines



Section 7

Troubleshooting

61145301

1-2013/Rev 02 7-3

Series 50 Troubleshooting Guide

Malfunction Indication Check

5. Plunger damage Cavitation effects Low supply water pressure

Air entering supply water line

Contaminated supply water Supply water quality or

chemistry




61145319HP

1-2013/Rev 0 8-1

SECTION 8

SPECIFICATIONS

8.1 Service Connections

Inlet Ports 3/4” NPT

Discharge Ports 3/8” HP

Cooling Water Ports 1/8” NPT

8.2 Lubrication Specifications

Series 50 pumps are splash lubricated by circulating oil or other specified lubricants in the

power e nd. To ensure proper power end lubrication, the oil must pour freely at lowest ambientoperating temperatures.

Refer to Section 5, Power End Assembly, for recommended power end lubricants and

maintenance intervals.



Section 8

Specifications

61145319HP

1-2013/Rev 0 8-2

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


Fluid End Assembly

Discharge Manifold

Cap Screws 6 (8”) each


Crossing Pattern


Transfer Block

Cap Screws 8 (45MM) each


Crossing Pattern8-Bolt Crossing Pattern

Plunger Assembly




Section 8

Specifications

61145319HP

1-2013/Rev 0 8-3

8.4 Water Quality Guidelines

The quality of the inlet water supply is one of the most important factors affecting component lifeand 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 8-2Water Quality Guidelines

TDS* Low TDS (< 100 ppm) Considered good water quality. Customer may

choose to use softening.

TDS Moderate TDS (100-200 ppm) Can be treated by softening or TDS reduction (RO

or DI)

TDS High TDS (> 200 ppm) Considered poor water quality. Should be treated

with RO or DI.

Silica High content (> 15 ppm) Dual string base DI

pH Treated water must have a value of 6 to 8

* Note: Total dissolved solids



Section 8

Specifications

61145319HP

1-2013/Rev 0 8-4

8.5 Nozzle Size Selector Chart

Nozzle Rating Flow (gpm)

Nozzle

Orifice

inch (mm)

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)

0.1 .008 (.207) 0.100 0.112 0.122 0.132 0.141 0.150 0.158 0.173 0.194 0.224 0.250 0.274 0.296 0.316

0.2 .012 (.293) 0.200 0.224 0.245 0.265 0.283 0.300 0.316 0.346 0.387 0.447 0.500 0.548 0.592 0.632

0.3 .014 (.358) 0.300 0.335 0.367 0.397 0.424 0.450 0.474 0.520 0.581 0.671 0.750 0.822 0.887 0.949

0.4 .016 (.414) 0.400 0.447 0.490 0.529 0.566 0.600 0.632 0.693 0.775 0.894 1.000 1.095 1.183 1.265

0.5 .018 (.463) 0.500 0.559 0.612 0.661 0.707 0.750 0.791 0.866 0.968 1.118 1.250 1.369 1.479 1.581

0.6 .020 (.507) 0.600 0.671 0.735 0.794 0.849 0.900 0.949 1.039 1.162 1.342 1.500 1.643 1.775 1.897

0.7 .022 (.547) 0.700 0.783 0.857 0.926 0.990 1.050 1.107 1.212 1.356 1.565 1.750 1.917 2.071 2.214

0.8 .023 (.585) 0.800 0.894 0.980 1.058 1.131 1.200 1.265 1.386 1.549 1.789 2.000 2.191 2.366 2.530

0.9 .024 (.621) 0.900 1.006 1.102 1.191 1.273 1.350 1.423 1.559 1.743 2.012 2.250 2.465 2.662 2.846

1.0 .026 (.654) 1.000 1.118 1.225 1.323 1.414 1.500 1.581 1.732 1.936 2.236 2.500 2.739 2.958 3.162

1.1 .027 (.686) 1.100 1.230 1.347 1.455 1.556 1.650 1.739 1.905 2.130 2.460 2.750 3.012 3.254 3.479

1.2 .028 (.717) 1.200 1.342 1.470 1.587 1.697 1.800 1.897 2.078 2.324 2.683 3.000 3.286 3.550 3.795

1.3 .029 (.746) 1.300 1.453 1.592 1.720 1.838 1.950 2.055 2.252 2.517 2.907 3.250 3.560 3.845 4.111

1.4 .030 (.774) 1.400 1.565 1.715 1.852 1.980 2.100 2.214 2.425 2.711 3.131 3.500 3.834 4.141 4.427

1.5 .032 (.801) 1.500 1.677 1.837 1.984 2.121 2.250 2.372 2.598 2.905 3.354 3.750 4.108 4.437 4.743

1.6 .033 (.827) 1.600 1.789 1.960 2.117 2.263 2.400 2.530 2.771 3.098 3.578 4.000 4.382 4.733 5.060

1.7 .034 (.853) 1.700 1.901 2.082 2.249 2.404 2.550 2.688 2.994 3.292 3.801 4.250 4.656 5.029 5.376

1.8 .035 (.878) 1.800 2.012 2.205 2.381 2.546 2.700 2.846 3.118 3.486 4.025 4.500 4.930 5.324 5.692

1.9 .035 (.902) 1.900 2.124 2.327 2.513 2.687 2.850 3.004 3.291 3.679 4.249 4.750 5.203 5.620 6.008



Section 8

Specifications

61145319HP

1-2013/Rev 0 8-5


Nozzle

Orifice

inch (mm)


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)

2.0 .036 (.925) 2.000 2.236 2.449 2.646 2.828 3.000 3.162 3.464 3.873 4.472 5.000 5.477 5.916 6.325

2.5 .041 (1.034) 2.500 2.795 3.062 3.307 3.536 3.750 3.953 4.330 4.841 5.590 6.250 6.847 7.395 7.906

3.0 .045 (1.133) 3.000 3.354 3.674 3.969 4.243 4.500 4.743 5.196 5.809 6.708 7.500 8.216 8.874 9.487

3.5 .048 (1.224) 3.500 3.913 4.287 4.630 4.950 5.250 5.534 6.062 6.778 7.826 8.750 9.585 10.353 11.068

4.0 .052 (1.308) 4.000 4.472 4.899 5.292 5.657 6.000 6.325 6.928 7.746 8.944 10.000 10.954 11.832 12.649

4.5 .055 (1.388) 4.500 5.031 5.511 5.953 6.364 6.750 7.115 7.794 8.714 10.062 11.250 12.324 13.311 14.230

5.0 .058(1.463) 5.000 5.590 6.124 6.614 7.071 7.500 7.906 8.660 9.682 11.180 12.500 13.693 14.790 15.811

5.5 .060 (1.534) 5.500 6.149 6.736 7.276 7.778 8.250 8.696 9.526 10.651 12.298 13.750 15.062 16.269 17.393

6.0 .063 (1.602) 6.000 6.708 7.348 7.937 8.485 9.000 9.487 10.392 11.619 13.416 15.000 16.432 17.748 18.974

6.5 .066 (1.668) 6.500 7.267 7.961 8.599 9.192 9.750 10.277 11.258 12.587 14.534 16.250 17.801 19.227 20.555

7.0 .068 (1.731) 7.000 7.826 8.573 9.260 9.900 10.500 11.068 12.124 13.555 15.653 17.500 19.170 20.706 22.136

7.5 .071 (1.791) 7.500 8.385 9.186 9.922 10.607 11.250 11.859 12.990 14.524 16.771 18.750 20.540 22.185 23.717

8.0 .073 (1.850) 8.000 8.944 9.798 10.583 11.314 12.000 12.649 13.856 15.492 17.889 20.000 21.909 23.664 25.298

8.5 .075 (1.907) 8.500 9.503 10.410 11.244 12.021 12.750 13.440 14.722 16.460 19.007 21.250 23.278 25.143 26.879

9.0 .077 (1.962) 9.000 10.062 11.023 11.906 12.728 13.500 14.230 15.589 17.428 20.125 22.500 24.648 26.622 28.461

9.5 .079 (2.016) 9.500 10.621 11.635 12.567 13.435 14.250 15.021 16.455 18.397 21.243 23.750 26.017 28.101 30.042

10.0 .081 (2.069) 10.000 11.180 12.247 13.229 14.142 15.000 15.811 17.321 19.365 22.361 25.000 27.386 29.580 31.623

11.0 .085 (2.170) 11.000 12.298 13.472 14.552 15.556 16.500 17.393 19.053 21.301 24.597 27.500 30.125 32.539 34.785

12.0 .089 (2.266) 12.000 13.416 14.697 15.875 163971 18.000 18.974 20.785 23.238 26.833 30.000 32.863 35.497 37.947

12.5 .091 (2.313) 12.500 13.975 15.309 16.536 17.678 18.750 19.764 21.651 24.206 27.951 21.250 34.233 36.976 39.529

13.0 .093 (2.359) 13.000 14.534 15.922 19.197 18.385 19.500 20.555 22.517 25.174 29.069 32.500 35.602 38.455 41.110



Section 8

Specifications

61145319HP

1-2013/Rev 0 8-6


Nozzle

Orifice

inch (mm)


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)

14.0 .096 (2.448) 14.000 15.653 17.146 18.520 19.799 21.000 22.136 24.249 27.111 31.305 35.000 38.341 41.413 44.272

15.0 .100 (2.533) 15.000 16.771 18.371 19.843 21.213 22.500 23.717 25.981 29.047 33.541 37.500 41.079 44.371 47.434



611453271-2013/Rev 02 9-1

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 StreetBaxter Springs, KS 66713

USA

Phone: (800) 826-9274

Fax: (620) 856-2242Email: [email protected]: [email protected]

KMT Aqua-Dyne Inc.PO Box 231635 West 12th StreetBaxter Springs, KS 66713

USA

Phone: 713-864-6929

Fax: 713-864-0313Email: [email protected]



PARENT: 61173682 TRPLX UNIT-BMX 25/50,50H15K4.9GC480AOLHUOM: EA DRAWING #: 61173682P

------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------Parent 61173682 TRPLX UNIT-BMX 25/50, EA AC

50H15K4.9GC480AOLH

Rev: 01 61172641 ITEM 01 TRPLX UNIT-BMX 25/50, 1.0 EA yes 61172641P AC

BASE UNITRev: 0

1 61172807 ITEM 02 KIT-CSTR,BMX 25/50 1.0 EA yes 61172807P ACRev: 1

1 61143929 ITEM 03 MTR-ELEC,50HP,326T, 1.0 EA SPEC SHT ACTEFC,230-460/3/60

Rev: 01 61173286 ITEM 04 KIT-MNTG,MTR,50HP, 1.0 EA yes 61173286P AC

BMX 25/50Rev: 0

1 61134070 ITEM 05 FL END ASSY-SERIES 50, 1.0 EA yes 11505-09 ACHP,20KSI,.56,AQD11505-09

Rev: 61 61173427 ITEM 06 KIT-BELT DR,BMX 25/50, 1.0 EA yes BOM ONLY AC

HI SPEED,50HPRev: 0

1 61173700 ITEM 07 KIT-ELEC,BMX 25/50,AOL, 1.0 EA 61173700P AC50HP,480/3/60

Rev: 01 61173708 ITEM 08 KIT-ACCESS,FL END, 1.0 EA yes 61173708P AC

BMX 25/50,.56MP,W/BYP

Rev: 01 20456034 ITEM 09 DISC-RUPT,.25 ANG,INCNL, 2.0 EA SPEC SHT AC18,000PSI

Rev: 01 61173682M ITEM 10 MAINT MNL-AQD,TRPLX 1.0 EA DOC AC

UNIT 61173682Rev: 0

End of Report

Prod Structure w/Drawing (KMT) 04/18/13 14:38:34

KMT Waterjet - PRODUCTION Page:1

Level Component Reference Description Qty Per UM Ph T Iss Start Eff End Eff Drawing Status

Page 1 of 2

4/18/2013http://bx-mfgvm.kmtwj.com:8080/wjprodUI/HTMLAdapter?processsequenceid=1468527...



PARENT: 61172641 TRPLX UNIT-BMX 25/50,BASE UNITUOM: EA DRAWING #: 61172641P

------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------Parent 61172641 TRPLX UNIT-BMX 25/50, EA Yes AC

BASE UNIT

Rev: 01 61172277 ITEM 01 FR ASSY-SERIES 25/50, 1.0 EA 61172277P AC

LIFTING FORKS,STDRev: 0

1 61142152 ITEM 02 PWR END ASSY-VF SERIES, 1.0 EA yes 61142152P ACMOD,DRAIN

Rev: 01 61172435 ITEM 03 BASE-PMP,SERIES 25/50, 1.0 EA 61172435P AC

ADJ,BENT,.38Rev: 1

1 61139623 ITEM 04 FLTR HSG ASSY-LP WTR, 1.0 EA SPEC SHT AC1.0 FNPT,AQD S23117-71

Rev: 01 61172443 ITEM 05 STUD-ADJ,SERIES 25/50, 4.0 EA 61172443P AC

1.0-8X5.50Rev: 0

1 61143937 ITEM 06 SPRKT-14MM PITCH,1.46W, 1.0 EA SPEC SHT AC90 TEETH

Rev: 01 61143963 ITEM 07 BSHG-SPLT,TPR,QD, 1.0 EA SPEC SHT AC

40MM ID,FRev: 0

1 05075734 ITEM 08 ELB-PIPE,.75X.75,F/M, 1.0 EA SPEC SHT AC

90D,SSTRev: 01 61104612 ITEM 09 ELB-PIPE,1.0X1.0,F/M, 3.0 EA SPEC SHT AC

90D,BRS,AQD S26005-03Rev: 0

1 61172599 ITEM 10 GA-PRESS,0-100PSI, 1.0 EA SPEC SHT AC.25NPT BACK CONN,PNL MNT

Rev: 01 61127419 ITEM 11 NPL-CLS,1.0,SCH40,BRS, 1.0 EA SPEC SHT AC

AQD S26535-00Rev: 0

1 61134328 ITEM 12 TEE-PIPE,1.0,F,BRS, 1.0 EA SPEC SHT ACAQD S26255-02

Rev: 01 61134294 ITEM 13 BSHG-PIPE,1.0X.25,M/F, 1.0 EA SPEC SHT AC

BRS,AQD S26161-02Rev: 0




Page 1 of 4





------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------1 95297628 ITEM 14 SCR-CAP,HX,1/2-13X1-1/4, 4.0 EA SPEC SHT AC

SST 316

Rev: 01 95413696 ITEM 15 WSHR-LOCK,.50X.125,SST 4.0 EA no SPEC SHT AC1 10078756 ITEM 16 BARB-HOSE,.25X.25 MNPTF, 2.0 EA SPEC SHT AC

STR,BRSRev: 0

1 95838314 ITEM 17 WSHR-LOCK,.25X.063,SST 6.0 EA no SPEC SHT ACRev: 0

1 95391322 ITEM 18 WSHR-FLAT,.25X.063,SST 6.0 EA no SPEC SHT ACRev: 0

1 95252193 ITEM 19 SCR-CAP,HX,1/4-20X1-1/4, 4.0 EA no SPEC SHT ACSST 316

Rev: 01 10078152 ITEM 20 BSHG-PIPE,.75X.50,M/F, 1.0 EA SPEC SHT AC

BRSRev: 2

1 49895303 ITEM 21 ADPTR-JIC/PIPE,.50X.50, 1.0 EA SPEC SHT ACM/M,STR,SST

Rev: 01 10173805 ITEM 22 ADPTR-HOSE/JIC,.50X.50, 1.0 EA no SPEC SHT AC

M/F,STR,BRS,SWVLRev: 1

1 61135980 ITEM 23 ADPTR-JIC/PIPE,1.0X1.0, 1.0 EA SPEC SHT ACM/M,STR,SST,S20500-23-SS

Rev: 01 61159764 ITEM 24 ADPTR-HOSE/JIC,1.0X1.0, 1.0 EA SPEC SHT ACSWVL,STR,BRS

Rev: 01 10079713 ITEM 25 BARB-HOSE,.50X.50 MNPTF, 1.0 EA SPEC SHT AC

STR,BRSRev: 3

1 61158435 ITEM 26 BARB-HOSE,1.0X1.0 NPT, 1.0 EA SPEC SHT ACBRS

Rev: 01 61172649 ITEM 27 WSHR-FLAT,1.0X.16,SST 8.0 EA SPEC SHT AC

Rev: 01 61172657 ITEM 28 NUT-JAM,1-8,SST 8.0 EA SPEC SHT AC

Rev: 01 61172675 ITEM 29 CPLG-PIPE,.25X.25,F/F, 1.0 EA SPEC SHT AC

BRSRev: 0




Page 2 of 4





------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------1 61134393 ITEM 30 DECL PKG-ELEC UNIT, 1.0 EA yes 30031-02 AC

NON CE MARK,AQD 30031-02

Rev: 11 61141565 ITEM 31 SCR-CAP,HX,M16X1.50X40MM 4.0 EA SPEC SHT AC

,GR-5,PLTDRev: 0

1 05035100 ITEM 32 WSHR-LOCK,M16,SST 4.0 EA SPEC SHT ACRev: 0

1 49881493 ITEM 33 SCR-CAP,HX,1/4-20X2, 2.0 EA SPEC SHT ACSST 316

Rev: 01 61172492 ITEM 34 DRAIN-LP,SERIES 25/50, 1.0 EA 61172492P AC

NYLRev: 0

1 61126172 ITEM 35 HOSE-PUSH ON,.25,BLUE, 10.0 IN SPEC SHT AC250 PSI,AQD S20226-XX

Rev: 01 20421272 ITEM 36 HOSE-PUSH ON,.50,BLUE, 20.0 IN SPEC SHT AC

300 PSIRev: 0

1 61159749 ITEM 37 HOSE-PUSH ON,1.0,BLUE, 25.0 IN SPEC SHT AC175 PSI

Rev: 01 61135574 ITEM 38 FLTR ELEM-LP WTR, 2.0 EA SPEC SHT AC

10 MICRON,10.0,S23117-74

Rev: 01 61172451 ITEM 39 BRKT-STRTR,SERIES 25/50 1.0 EA 61172451P ACRev: 0

1 95660957 ITEM 40 WSHR-FLAT,.38X.078,SST 4.0 EA no SPEC SHT AC1 61113035 ITEM 41 NUT-LOCK,3/8-16, 2.0 EA SPEC SHT AC

SST,NYL INSR,S29570-02Rev: 0

1 95251765 ITEM 42 SCR-CAP,HX,3/8-16X3, 2.0 EA SPEC SHT ACSST 316

Rev: 0

End of Report




Page 3 of 4




PARENT: 61134070 FL END ASSY-SERIES 50,HP,20KSI,.56,AQD11505-09UOM: EA DRAWING #: 11505-09

------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------Parent 61134070 FL END ASSY-SERIES 50, EA Yes AC

HP,20KSI,.56,AQD11505-09

Rev: 61 61145600 ITEM 01 BLK-XFR,SERIES 50,20KSI, 1.0 EA 01/08/10 61145600P AC

INTGRL GDERev: 2

1 61126932 ITEM 02 BLK-MDLR,SERIES 50, 1.0 EA 40045-04 AC20KSI,AQD 40045-04

Rev: 11 61134765 ITEM 03 SCR-CAP,SKT,3/4-10X8, 6.0 EA 09/16/09 SPEC SHT AC

PLTD,AQD S28258-29Rev: 1

1 61148045 ITEM 04 SCR-CAP,SKT,M12X1.75X45 8.0 EA 04/07/10 SPEC SHT ACMM,18-8 SST

Rev: 01 61127627 ITEM 06 PLGR ASSY-EK III,.56, 3.0 EA 40101-09 AC

AQD 40101-09Rev: 0

1 61135814 ITEM 07 RNG-RTNG,INT,1.25,SST, 3.0 EA 10/16/09 SPEC SHT AC2 TURN,AQD S29450-77

Rev: 01 61127007 ITEM 08 HLDR-SEAL,LP,.56, 3.0 EA 40074-09 AC

EKIII,AQD 40074-09Rev: 1

1 61141583 ITEM 09 SEAL ASSY-LP,.56, 3.0 EA B19406-09 AC

AQD B19406-09Rev: 01 20413913 ITEM 10 O RNG-023,1.06X1.19X.06, 3.0 EA 10/16/09 SPEC SHT AC

BN-N,D-70Rev: 0

1 20430013 ITEM 11 O RNG-032,1.88X2.0X.06, 6.0 EA 10/16/09 SPEC SHT ACBN-N,D-70

Rev: 01 20434215 ITEM 12 O RNG-034,2.11X2.25X.07, 3.0 EA 10/16/09 SPEC SHT AC

BN-N,D-70Rev: 0

1 61124949 ITEM 13 SEAT-PKG,.56X1.0, 3.0 EA A19596-09 ACAQD A19596-09

Rev: 61 61114033 ITEM 14 PKG-REAR,1.0X.56X.19, 3.0 EA 09/15/09 A29025-09 AC

PLSTC,HP,AQD A29025-09Rev: 3




Page 1 of 3




PARENT: 61134070 FL END ASSY-SERIES 50,HP,20KSI,.56,AQD11505-09UOM: EA DRAWING #: 11505-09

------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------1 61124636 ITEM 15 PKG-FRNT,1.0X.56X.19, 6.0 EA B29056-09 AC

TFLN GLS,HP,B29056-09

Rev: 41 61134757 ITEM 16 SPCR-SPR,SERIES 50,20KSI 3.0 EA 40063-09 AC

,.56 PLGR,AQD 40063-09Rev: 1

1 61120199 ITEM 17 SPR-CPRSN,.975X.074X1.50 3.0 EA 10/13/09 SPEC SHT AC,SST,AQD S24135-00

Rev: 01 61135748 ITEM 18 VLV-SUCT,SERIES 50, 3.0 EA 10/13/09 40019-00 AC

HP,20KSI,AQD 40019-00Rev: 1

1 61141955 ITEM 19 BARL-SERIES 50,20KSI 3.0 EA 07/22/09 61141955P ACRev: 2

1 61117267 ITEM 20 SEAL-CPRSN,1.00X1.25, 3.0 EA A29012-33 ACAQD A29012-33

Rev: 11 61117316 ITEM 21 SEAL-CPRSN,1.125ID,GA 3.0 EA 09/15/09 A29012-34 AC

SER,VHP,AQD A29012-34Rev: 1

1 61119277 ITEM 22 SEAT-VLV,SERIES 250, 3.0 EA B19405-33 ACUHP,AQD B19405-33

Rev: 51 61121927 ITEM 23 VLV-DISCH,SERIES 250, 3.0 EA B19414-24 AC

UHP,AQD B19414-24

Rev: 81 61120274 ITEM 24 SPR-CPRSN,.36X.047X1.12, 3.0 EA 11/09/00 SPEC SHT ACSST,AQD S24103-34

Rev: 01 61135756 ITEM 25 GDE-VLV,DISCH,SERIES 100 3.0 EA 10/13/09 40099-00 AC

,40KSI,AQD 40099-00Rev: 1

End of Report




Page 2 of 3




PARENT: 61173708 KIT-ACCESS,FL END,BMX 25/50,.56MP,W/BYPUOM: EA DRAWING #: 61173708P

------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------Parent 61173708 KIT-ACCESS,FL END, EA Yes AC

BMX 25/50,.56MP,W/BYP

Rev: 01 20441750 ITEM 01 VLV ASSY-MP,2 WAY ANG, 1.0 EA SPEC SHT AC

.56,20KSIRev: 1

1 49879216 ITEM 02 GLND-TBE,MP,.56,SST, 3.0 EA SPEC SHT AC20KSI

Rev: 01 05075585 ITEM 03 SFTY HD ASSY-MP,.56, 1.0 EA SPEC SHT AC

20KSI,.25 ANG DISCRev: 0

1 61104570 ITEM 04 ELB-PIPE,.38X.38,F/M, 1.0 EA SPEC SHT AC90D,SST,AQD S26002-01

Rev: 01 61110056 ITEM 05 NPL-CLS,.75,SCH40,SST, 1.0 EA SPEC SHT AC

AQD S26620-00Rev: 0

1 05075726 ITEM 06 TEE-PIPE,.75,F,SST 1.0 EA SPEC SHT ACRev: 0

1 61156351 ITEM 07 ELB-PIPE,.75X.75,F/M, 2.0 EA SPEC SHT AC90D,BRS

Rev: 01 61100859 ITEM 08 ADPTR-JIC/PIPE,.75X.75, 1.0 EA SPEC SHT AC

M/M,STR,SST,S20500-19-SS

Rev: 01 20423696 ITEM 09 ADPTR-HOSE/JIC,.75X.75, 1.0 EA SPEC SHT ACM/F,STR,BRS,SWVL

Rev: 01 05091129 ITEM 10 BSHG-PIPE,.75X.25,M/F, 2.0 EA SPEC SHT AC

BRSRev: 0

1 10124246 ITEM 11 ADPTR-JIC/PIPE,.25X.25, 2.0 EA SPEC SHT ACM/M,STR,BRS

Rev: 01 10174605 ITEM 12 BARB-HOSE,.25X.25 FJIC, 4.0 EA SPEC SHT AC

SWVL,STR,BRSRev: 0

1 10093581 ITEM 13 ELB-PIPE,.25X.25,F/M, 1.0 EA SPEC SHT AC90D,BRS

1 61135840 ITEM 14 ADPTR-JIC/PIPE,.25X.13, 2.0 EA SPEC SHT ACM/M,90D,AQD S20502-02-SS

Rev: 0




Page 1 of 3




PARENT: 61173708 KIT-ACCESS,FL END,BMX 25/50,.56MP,W/BYPUOM: IN DRAWING #: 61173708P

------ ------------------ ------------ ------------------------ --------- -- --- - --- --------- -------- ------------------ -------1 61126172 ITEM 15 HOSE-PUSH ON,.25,BLUE, 24.0 IN SPEC SHT AC

250 PSI,AQD S20226-XX

Rev: 01 05076021 ITEM 17 TBE-MP,.56X.312X4.0, 2.0 EA SPEC SHT AC

SST316,C/T BTH ENDS,20KRev: 3

1 61131939 ITEM 18 CLR-TBE,MP,.56,SST, 3.0 EA SPEC SHT AC20KSI,AE,S21639-61-AE

Rev: 01 10103265 ITEM 19 BARB-HOSE,.75X.75 MNPTF, 1.0 EA SPEC SHT AC

STR,BRSRev: 0

1 61102377 ITEM 20 BSHG-PIPE,1.0X.75,M/F, 1.0 EA SPEC SHT ACSST,AQD S26164-01


250 PSI,AQD S20243-XXRev: 0

1 61105825 ITEM 22 GA-PRESS,0-20,000PSI, 1.0 EA SPEC SHT AC.56MP,SST,AQD S23002-25

Rev: 01 20457105 ITEM 23 ADPTR ASSY-MP/PIPE, 1.0 EA SPEC SHT AC

.56X.50,M/F,STR,SST,15KRev: 0

1 10113959 ITEM 24 ELB-PIPE,.50X.50,F/M, 1.0 EA SPEC SHT AC

90D,SSTRev: 01 20412437 ITEM 25 BSHG-PIPE,.75X.50,M/F, 1.0 EA SPEC SHT AC

BRS/BRZRev: 0

1 10079713 ITEM 26 BARB-HOSE,.50X.50 MNPTF, 2.0 EA SPEC SHT ACSTR,BRS


300 PSIRev: 0

End of Report




Page 2 of 3




Item No. : 37420 / IDH No. 487231 Product name: Loctite(R) High Strength Threadlocker 2621 of 4

Material Safety Data Sheet

Revision Date: 06/25/2008 Issue date: 06/25/2008

1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

Product name: Loctite(R) High Strength Threadlocker 262 Item No. : 37420 / IDH No. 487231Product type: Anaerobic Sealant Region: United StatesCompany address:Henkel CorporationOne Henkel WayRocky Hill, Connecticut 06067

Contact Information:Telephone: (860) 571-5100Emergency telephone: (860) 571-5100Internet: www.henkelna.com

2. COMPOSITION/INFORMATION ON INGREDIENTS

Hazardous components % ACGIH TLV OSHA PEL OTHER

Polyglycol dimethacrylate25852-47-5

60-100 None None None

Bisphenol A fumarate resin39382-25-7

10-30 None None None

Saccharin81-07-2

1-5 None None None

Cumene hydroperoxide80-15-9

1-5 None None 1 ppm (6 mg/m3) Skin (WEEL)

3. HAZARDS IDENTIFICATION

EMERGENCY OVERVIEWHMIS:

Physical state: Liquid HEALTH: 2*Color: Red FLAMMABILITY: 1Odor: Mild PHYSICAL HAZARD: 1

Personal Protection: See Section 8

WARNING: CAUSES EYE IRRITATION.MAY CAUSE ALLERGIC SKIN REACTION.MAY CAUSE RESPIRATORY TRACT IRRITATION.MAY CAUSE SKIN IRRITATION.

Relevant routes of exposure: Skin, Inhalation, Eyes, Respiratory system

Potential Health Effects

Inhalation: May cause respiratory tract irritation.Skin contact: May cause allergic skin reaction. May cause skin i rritation with discomfort or rash.Eye contact: Contact with eyes will cause irritation.Ingestion: May be harmful if swallowed.

Existing conditions aggravated byexposure:

Eye, skin, and respiratory disorders.

See Section 11 for additional toxicological information.

KMT 61144666




4. FIRST AID MEASURES

Inhalation: Remove to fresh air. If symptoms develop and persist, get medical attention.

Skin contact: Wash with soap and water. Remove contaminated clothing and shoes. Wash clothing before reuse.Get medical attention if symptoms occur.

Eye contact: Flush with copious amounts of water, preferably, lukewarm water for at least 15 minutes, holdingeyelids open all the time. Get medical attention.

Ingestion: Do not induce vomiting. Keep individual calm. Obtain medical attention.

5. FIRE-FIGHTING MEASURES

Flash point: Greater than 93ºC (200ºF) Tagliabue closed cup

Autoignition temperature: Not available

Flammable/Explosive limits-lower %: Not available

Flammable/Explosive limits-upper %: Not available

Extinguishing media: If product is involved in fire extinguish with dry powder, foam or carbon dioxide.

Special fire fighting procedures: Wear self contained breathing apparatus

Unusual fire or explosion hazards: None

Hazardous combustion products: Thermal decomposition can lead to release of i rritating gases and vapors. Oxides of carbon. Oxides of nitrogen.

6. ACCIDENTAL RELEASE MEASURES

Environmental precautions: Ventilate area. Prevent product from entering drains or open waters.

Clean-up methods: 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.

Storage: For safe storage, store at or below 38°C (100°F). Keep in a cool, well ventilated area away from heat,sparks and open flame. Keep container tightly closed until ready for use.

Incompatible products: Refer to Section 10.

For information on product shelf life contact Henkel Customer Service at (800) 243-4874.

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

Engineering controls: No specific ventilation requirements noted, but forced ventilation may still be required if concentrationsexceed occupational exposure limts.

Respiratory protection: Use a NIOSH approved air purifying respirator with an organic vapor cartridge if the potential to exceedestablished exposure limits exists.

Skin protection: Use impermeable gloves and protective clothing as necessary to prevent skin contact. Neoprenegloves. Butyl rubber gloves. Natural rubber gloves.

Eye/face protection: Safety goggles or safety glasses with side shields.

See Section 2 for exposure limits.

KMT 61144666




9. PHYSICAL AND CHEMICAL PROPERTIES

Physical state: LiquidColor: RedOdor: MildVapor pressure: Less than 5 mm Hg at 27ºC (80ºF)pH: Not applicableBoiling point/range: Greater than 149ºC (300ºF)Melting point/range: Not availableSpecific gravity: 1.05Vapor density: Not availableEvaporation rate: Not availableSolubility in water: SlightPartition coefficient (n-octanol/water): Not availableVOC content: 0.0%; 0 grams/liter

10. STABILITY AND REACTIVITY

Stability: Stable.

Hazardous polymerization: Will not occur.

Hazardous decomposition products: Oxides of carbon. Oxides of sulfur. Oxides of nitrogen. Irritating organic vapors. Phenols.

Incompatability: Iron. Copper. Rust. Aluminum. Zinc. Reducing agents. Strong acids and oxidizing agents. Oxygenscavengers. Strong alkalis.

Conditions to avoid: See "Handling and Storage" (Section 7) and "Incompatabilty" (Section 10).

11. TOXICOLOGICAL INFORMATION

Product toxicity data: Acute oral LD50 greater than 10, 000 mg/kg (rat). Acute dermal LD50 greater than 5000 mg/kg (rabbit).

Carcinogen Status

Hazardous components NTP Carcinogen IARC Carcinogen OSHA Carcinogen


No No No


No No No

Saccharin81-07-2

No No No

Cumene hydroperoxide

80-15-9

No No No

Literature Referenced Target Organ & Other Health Effects

Hazardous components Health Effects/Target Organs


Allergen, Irritant


Allergen, Irritant

Saccharin81-07-2

No Target Organs

Cumene hydroperoxide80-15-9

Allergen, Central nervous system, Corrosive, Irritant, Mutagen

12. ECOLOGICAL INFORMATION

Ecological information: Not available

KMT 61144666




13. DISPOSAL CONSIDERATIONS

Information provided is for unused product only.

Recommended method of disposal: Dispose of according to Federal, State and local governmental regulations.

EPA hazardous waste number: Not a RCRA hazardous waste.

14. TRANSPORT INFORMATION

U.S. Department of Transportation Ground (49 CFR):Proper shipping name: Unrestricted

Hazard class or division: NoneIdentification number: NonePacking group: None

International Air Transportation (ICAO/IATA):Proper shipping name: UnrestrictedHazard class or division: NoneIdentification number: NonePacking group: None

WaterTransportation (IMO/IMDG):Proper shipping name: UnrestrictedHazard class or division: NoneIdentification number: NonePacking group: NoneMarine pollutant: None

15. REGULATORY INFORMATION

United States Regulatory Information

TSCA 8 (b) Inventory Status: All components are listed or are exempt from listing on the Toxic Substances Control Act Inventory.TSCA 12 (b) Export Notification: None.

CERCLA/SARA Section 302 EHS: None above reporting de minimus.CERCLA/SARA Section 311/312: Immediate Health Hazard, Delayed Health HazardCERCLA/SARA 313: This product contains the following toxic chemicals subject to the reporting requirements of section 313

of the Emergency Planning and Community Right-To-Know Act of 1986 (40 CFR 372). Cumenehydroperoxide (CAS# 80-15-9) .

California Proposition 65: No California Proposition 65 listed chemicals are known to be present.

Canada Regulatory Information

CEPA DSL/NDSL Status: All components are listed on or are exempt from listing on the Domestic Substances List.WHMIS hazard class: 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 Corporationdoes not assume responsibility for any results obtained by persons over whose methods Henkel Corporation has no control. It is theuser'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 beinvolved in the handling and use of any of Henkel Corporation's products. In light of the foregoing, Henkel Corporation specificallydisclaims all warranties, express or implied, including warranties of merchantability and fitness for a particular purpose, arising fromsale or use of Henkel Corporation's products. Henkel Corporation further disclaims any liability for consequential or incidental damagesof any kind, including lost profits.

KMT 61144666



1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION


Hazardous components % ACGIH TLV OSHA PEL OTHER

Distillates (petroleum), hydrotreatedheavy naphthenic64742-52-5

30-60 5 mg/m³ TWA (mist)10mg/m³ STEL (mist)

5 mg/m³ TWA (mist) None

Graphite7782-42-5

10-30 2 mg/m³ TWA respirablefraction, all forms except

graphite fibers

15 mg/m³ (total), 5 mg/m³(respirable)

None

Calcium oxide1305-78-8

10-30 2 mg/m³ TWA 5 mg/m³ (TWA) None

Distillates (petroleum), hydrotreatedlight naphthenic64742-53-6


5 mg/m³TWA ( mist) None

Aluminum7429-90-5

5-10 10 mg/m³ TWA metal dust5 mg/m³ TWA as Al

15 mg/m³ TWA (total), 5mg/m³( respirable)

None

Distillates (petroleum), straight-runmiddle64741-44-2


5 mg/m³ mist None

Silica, quartz14808-60-7

0.1-1 0.05 mg/m³ TWArespirable fraction

0.1mg/m³ TWA(respirable)

None


Relevant routes of exposure: Skin, Inhalation, Eyes

Potential Health Effects

Inhalation: Moderate respiratory tract irritation.Skin contact: Moderate skin irritation.Eye contact: Moderate eye irritation.

1 of 5

06/05/2006

Product name: Silver Grade Anti-Seize Lubricant

Issue date: 06/05/2006

Item No. : 76764

Material Safety Data Sheet

Product type: Lubricant Region: United States

Company address:Henkel Corporation1001 Trout Brook CrossingRocky Hill, Connecticut 06067

Revision Date:

Contact Information:Telephone: 860.571.5100Emergency telephone: 860.571.5100Internet: www.loctite.com

EMERGENCY OVERVIEW

Item No. : 76764 Product name: Silver Grade Anti-Seize Lubricant

Color: Silver FLAMMABILITY: 1

Odor: Hydrocarbon-like

PHYSICAL HAZARD: 1

Physical state: Paste

Personal Protection: See Section 8

HEALTH: 1

WARNING: CAUSES EYE, SKIN AND RESPIRATORY TRACT IRRITATION

HMIS:

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Ingestion: Ingestion may cause gastrointestinal irritation, nausea, vomiting and diarrhea. Principal hazard of ingestion is aspiration into the lungs and subsequent pneumonitis.

Existing conditions aggravated byexposure:

Eye, skin, and respiratory disorders.

See Section 11 for additional toxicological information.

4. FIRST AID MEASURES

Inhalation: Remove to fresh air. If discomfort persists seek medical attention.

Skin contact: Wash with soap and water. If symptoms persist, obtain medical attention.

Eye contact: Immediately flush eyes with plenty of water for at least 15 minutes. Get medical attention.

Ingestion: Do not induce vomiting. Get medical attention immediately.

5. FIRE-FIGHTING MEASURES

Flash point: >93°C (>200°F)

Autoignition temperature: Not determined

Flammable/Explosive limits-lower %: Not available

Flammable/Explosive limits-upper %: Not available

Extinguishing media: Carbon dioxide (CO2). Foam. Dry chemical.

Special fire fighting procedures: None

Unusual fire or explosion hazards: None

Hazardous combustion products: Oxides of carbon. Oxides of nitrogen.

6. ACCIDENTAL RELEASE MEASURES

Environmental precautions: Prevent further leakage or spillage.

Clean-up methods: Remove all ignition sources. Soak up with inert absorbent. Store in a closed container until ready for disposal.

7. HANDLING AND STORAGE

Handling: Keep away from heat, spark and flame. Avoid contact with skin and eyes.

Storage: Keep in a cool, well ventilated area.

Incompatible products: 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 belowestablished exposure limits.

Respiratory protection: Use NIOSH approved respirator if there is potential to exceed exposure limit(s).

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76764Item No. : Product name: Silver Grade Anti-Seize Lubricant

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Skin protection: Neoprene or oil resistant gloves

Eye/face protection: Safety goggles or safety glasses with side shields.

See Section 2 for exposure limits.

9. PHYSICAL AND CHEMICAL PROPERTIES

Physical state: Paste

Color: Silver Odor: Hydrocarbon-likeVapor pressure: <5 mmHg @20°C (68° F)pH: Not applicableBoiling point/range: Not availableMelting point/range: Not availableSpecific gravity: 1.25Vapor density: Not availableEvaporation rate: Not availableSolubility in water: InsolublePartition coefficient (n-octanol/water): Not determinedVOC content: 12.96%; 162 grams/liter

10. STABILITY AND REACTIVITY

Stability: Stable.

Hazardous polymerization: Will not occur.

Hazardous decomposition products: None reasonably foreseeable

Incompatability: Strong oxidizing agents.

Conditions to avoid: None known.

11. TOXICOLOGICAL INFORMATION

Carcinogen Status

Hazardous components NTP Carcinogen IARC Carcinogen OSHA Carcinogen


No No No

Graphite7782-42-5

No No No


No No No


No No No

Aluminum7429-90-5

No No No

Distillates (petroleum), straight-runmiddle

64741-44-2

No No No


Known Carcinogen Group 1 Yes

Literature Referenced Target Organ & Other Health Effects

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Hazardous components Health Effects/Target Organs


Irritant

Graphite7782-42-5

Lung


Irritant, Eyes, Corrosive


Irritant

Aluminum7429-90-5

Central nervous system, Irritant, Lung

Distillates (petroleum), straight-runmiddle64741-44-2

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: Dispose of according to Federal, State and local governmental regulations.

EPA hazardous waste number: Not a RCRA hazardous waste.


U.S. Department of Transportation Ground (49 CFR):Proper shipping name: UnrestrictedHazard class or division: NoneIdentification number: NonePacking group: None

International Air Transportation (ICAO/IATA):Proper shipping name: UnrestrictedHazard class or division: NoneIdentification number: NonePacking group: None

WaterTransportation (IMO/IMDG):Proper shipping name: UnrestrictedHazard class or division: NoneIdentification number: NonePacking group: NoneMarine pollutant: None

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15. REGULATORY INFORMATION

United States Regulatory Information

TSCA 8 (b) Inventory Status: All components are listed or are exempt from listing on the Toxic Substances Control Act Inventory.TSCA 12 (b) Export Notification: None.

CERCLA/SARA Section 302 EHS: None.CERCLA/SARA Section 311/312: Immediate Health HazardCERCLA/SARA 313: Aluminum (CAS# 7429-90-5) (dust and fumes only).

California Proposition 65: No California Proposition 65 listed chemicals are known to be present.

Canada Regulatory Information

CEPA DSL/NDSL Status: All components are listed on or are exempt from listing on the Domestic Substances List.WHMIS hazard class: 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 Corporationdoes not assume responsibility for any results obtained by persons over whose methods Henkel Corporation has no control. It is theuser'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 beinvolved in the handling and use of any of Henkel Corporation's products. In light of the foregoing, Henkel Corporation specificallydisclaims all warranties, express or implied, including warranties of merchantability and fitness for a particular purpose, arising from saleor use of Henkel Corporation's products. Henkel Corporation further disclaims any liability for consequential or incidental damages of any kind, including lost profits.

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LUBRIPLATE

MATERIAL SAFETY DATA SHEET

Section 1

PRODUCT NAME OR NUMBER: FORMULA:

LUBRIPLATE Super FML-0, FML-1, FML-2 Calcium Soap, USP Mineral Oil and Additives

GENERIC/CHEMICAL NAME: NSF Registration No’s:

Petroleum Lubricating Grease 125742, 125740, 125741

Manufacturer's Name: Emergency Telephone Number:

Fiske Brothers Refining Co. 1-800-255-3924 - CHEM-TEL (24 hour)

Address: Telephone Number for Information:

1500 Oakdale Ave., Toledo, Ohio 43605 - 129 Lockwood St., Newark, NJ 07105 419-691-2491 - Toledo Office

Section 2 - Hazardous Ingredients/Identity Information

Hazardous Components OSHA PEL ACGIH TLV Other Limits Recommended % (optional)

Non-hazardous

Hazardous Material Identification System (HMIS): Health - 1, Flammability - 1, Reactivity - 0

Not a Controlled Product under (WHMIS) - Canada Special Protection: See Section 9

Section 3 - Health Hazard Data

Threshold Limit Value: 5 mg/m3 for oil mist in air. OSHA Regulation 29 CFR 1910.1000

Effects of Overexposure: Prolonged or repeated skin contact may cause skin irritation. Product contacting the eyes may cause eye

irritation. Human health risks vary from person to person. As a precaution, exposure to liquids, vapors, mists and fumes should be

minimized. This product has a low order of acute oral toxicity, but minute amounts aspirated into the lungs during ingestion may cause mild

to severe pulmonary injury.

Carcinogenicity: NTP? No IARC Monographs? No OSHA Regulated? No

Section 4 - Emergency and First Aid Procedures

EYE CONTACT: Flush with clear water for 15 minutes or until irritation subsides. If irritation persists, consult a physician.

SKIN CONTACT: Remove any contaminated clothing and wash with soap and warm water. If injected by high pressure under skin,

regardless of the appearance or its size, contact a physician IMMEDIATELY. Delay may cause loss of affected part of the body.

INHALATION: Vapor pressure is very low and inhalation at room temperature is not a problem. If overcome by vapor from hot product,

immediately remove from exposure and call a physician.

INGESTION: If ingested, call a physician immediately. Do not induce vomiting.

Section 5 - Fire and Explosion Hazard Data

Flash Point (Method Used): COC - 435oF Flammable Limits: LEL 0.9% UEL 7.0%

Extinguishing Media: Foam, Dry Chemical, Carbon Dioxide or Water Spray (Fog)

Special Fire Fighting Procedures: Cool exposed containers with water. Use air-supplied breathing equipment for

enclosed or confined spaces.

Unusual Fire and Explosion Hazards: Do not store or mix with strong oxidants. Empty containers retain residue.

Do not cut, drill, grind, or weld, as they may explode.

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PRODUCT NAME OR NUMBER - LUBRIPLATE Super FML-0, FML-1, FML-2

Section 6 - Physical/Chemical Characteristics

Boiling Point: >550oF Specific Gravity (H 2O = 1): 0.90 - 0.91

Vapor Pressure (mm Hg.): <0.01 Melting Point: Semi-solid

Vapor Density (AIR = 1): >5 Evaporation Rate: <0.01

(Butyl Acetate = 1)

Solubility in Water: Negligible

Appearance and Odor: Smooth, white grease with mineral oil odor.

Section 7 - Reactivity Data

Stability: Unstable Conditions to Avoid: N/A

Stable X

Incompatibility (Materials to Avoid): Avoid contact with strong oxidants like liquid chlorine, concentrated oxygen.

Hazardous Decomposition or Byproducts: May form SO 2. If incomplete combustion, Carbon Monoxide.

Hazardous Polymerization: May Occur Conditions to Avoid: N/A

Will Not Occur X

Section 8 - Spill or Leak Procedures

Steps to be taken in case material is released or spilled:

Scrape up grease, wash remainder with suitable petroleum solvent or add absorbent. Keep petroleum products out of sewers and

watercourses. Advise authorities if product has entered or may enter sewers and watercourses.

Waste disposal method:

Assure conformity with applicable disposal regulations. Dispose of absorbed material at an approved waste disposal facility or site.

SARA/TITLE III, Section 313 Status - Zinc Compounds - <6%

Section 9 - Special Protection Information

Respiratory Protection (Specify type): Normally not needed

Ventilation Local Exhaust: Used to capture fumes and vapors Special: N/A

Mechanical (General) Other: N/A

Protective Gloves: Use oil-resistant gloves, if needed. Eye Protection: If chance of eye contact, wear goggles.

Other Protective Equipment: Use oil-resistant apron, if needed.

Section 10 - Special Precautions

Precautions to be taken in handling and storing:

Keep containers closed when not in use. Do not handle or store near heat, sparks, flame, or strong oxidants.

Other Precautions: Remove oil-soaked clothing and launder before reuse. Cleanse skin thoroughly after contact.

The above information is furnished without warranty, expressed or implied, except that it is accurate to the best knowledge of Fiske

Brothers Refining Company. The data on these sheets relates only to the specific material designated herein. Fiske Brothers

Refining Company assumes no legal responsibility for use or reliance upon this data.

Date Prepared: January, 2006 Prepared by: James R. Kontak

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Morlina® Oil SD 100MSDS# 61044E

Version 7.1Effective Date 01/06/2009

Material Safety Data Sheet According to OSHA Hazard Communication Standard, 29 CFR

1910.1200

1/7Print Date 02/12/2009 MSDS_US

1. MATERIAL AND COMPANY IDENTIFICATION Material Name : Morlina® Oil SD 100

Manufacturer/Supplier : SOPUS Products PO BOX 4427Houston, TX 77210-4427USA

MSDS Request : 877-276-7285

Emergency Telephone Number Spill Information : 877-242-7400Health Information : 877-504-9351


Highly refined mineral oils and additives. The highly refined mineral oil contains <3% (w/w) DMSO-extract, according to IP346.


Emergency Overview Appearance and Odour : Clear pale yellow. Liquid at room temperature. Slight

hydrocarbon.

Health Hazards : Not classified as dangerous for supply or conveyance. Safety Hazards : Not classified as flammable but will burn. Environmental Hazards : Not classified as dangerous for the environment.

Health Hazards : Not expected to be a health hazard when used under normalconditions.

Health Hazards Inhalation : Under normal conditions of use, this is not expected to be a

primary route of exposure.

Skin Contact : Prolonged or repeated skin contact without proper cleaning canclog the pores of the skin resulting in disorders such as oilacne/folliculitis.

Eye Contact : May cause slight irritation to eyes. Ingestion : Low toxicity if swallowed.Other Information : Used oil may contain harmful impurities.

Signs and Symptoms : Oil acne/folliculitis signs and symptoms may include formationof black pustules and spots on the skin of exposed areas.Ingestion may result in nausea, vomiting and/or diarrhoea.

Aggravated MedicalCondition

: Pre-existing medical conditions of the following organ(s) or organ system(s) may be aggravated by exposure to thismaterial: Skin.

Environmental Hazards : Not classified as dangerous for the environment.

Additional Information : Under normal conditions of use or in a foreseeable emergency,

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this product does not meet the definition of a hazardouschemical when evaluated according to the OSHA HazardCommunication Standard, 29 CFR 1910.1200.

4. FIRST AID MEASURES General Information : Not expected to be a health hazard when used under normal

conditions.Inhalation : No treatment necessary under normal conditions of use. If

symptoms persist, obtain medical advice.Skin Contact : Remove contaminated clothing. Flush exposed area with water

and follow by washing with soap if available. If persistent

irritation occurs, obtain medical attention.Eye Contact : Flush eye with copious quantities of water. If persistent

irritation occurs, obtain medical attention.Ingestion : In general no treatment is necessary unless large quantities

are swallowed, however, get medical advice.Advice to Physician : Treat symptomatically.

5. FIRE FIGHTING MEASURES Clear fire area of all non-emergency personnel.

Flash point : Typical 218 °C / 424 °F (COC) Upper / lower

Flammability or Explosion limits

: Typical 1 - 10 %(V)(based on mineral oil)

Auto ignition temperature : > 320 °C / 608 °F Specific Hazards : Hazardous combustion products may include: A complex

mixture of airborne solid and liquid particulates and gases(smoke). Carbon monoxide. Unidentified organic and inorganiccompounds.

Suitable ExtinguishingMedia

: Foam, water spray or fog. Dry chemical powder, carbondioxide, sand or earth may be used for small fires only.

Unsuitable ExtinguishingMedia

: Do not use water in a jet.

Protective Equipment for Firefighters

: Proper protective equipment including breathing apparatusmust 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 protectiveequipment see Chapter 8 of this Material Safety Data Sheet. See Chapter 13 for information ondisposal. Observe all relevant local and international regulations.

Protective measures : Avoid contact with skin and eyes. Use appropriate containmentto avoid environmental contamination. Prevent from spreadingor entering drains, ditches or rivers by using sand, earth, or other appropriate barriers.

Clean Up Methods : 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

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absorbent. Soak up residue with an absorbent such as clay,sand or other suitable material and dispose of properly.

Additional Advice : Local authorities should be advised if significant spillagescannot 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 anycontaminated rags or cleaning materials in order to preventfires. Use the information in this data sheet as input to a riskassessment of local circumstances to help determine

appropriate controls for safe handling, storage and disposal of this material.

Handling : Avoid prolonged or repeated contact with skin. Avoid inhalingvapour and/or mists. When handling product in drums, safetyfootwear should be worn and proper handling equipmentshould be used.

Storage : Keep container tightly closed and in a cool, well-ventilatedplace. Use properly labelled and closeable containers. StorageTemperature: 0 - 50 °C / 32 - 122 °F

Recommended Materials : For containers or container linings, use mild steel or highdensity polyethylene.

Unsuitable Materials : PVC.Additional Information : Polyethylene containers should not be exposed to high

temperatures because of possible risk of distortion.

8. EXPOSURE CONTROLS/PERSONAL PROTECTION Occupational Exposure Limits

Material Source Type ppm mg/m3 Notation

Oil mist,mineral

ACGIH TWA(Mist.) 5 mg/m3

Oil mist,mineral

ACGIH STEL(Mist.) 10 mg/m3

Exposure Controls : The level of protection and types of controls necessary will varydepending upon potential exposure conditions. Select controlsbased on a risk assessment of local circumstances. Appropriate measures include: Adequate ventilation to controlairborne concentrations. Where material is heated, sprayed or mist formed, there is greater potential for airborneconcentrations to be generated.

Personal ProtectiveEquipment

: Personal protective equipment (PPE) should meetrecommended national standards. Check with PPE suppliers.

Respiratory Protection : No respiratory protection is ordinarily required under normalconditions of use. In accordance with good industrial hygienepractices, precautions should be taken to avoid breathing of material. If engineering controls do not maintain airborne

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concentrations to a level which is adequate to protect worker health, select respiratory protection equipment suitable for thespecific conditions of use and meeting relevant legislation. Check with respiratory protective equipment suppliers. Whereair-filtering respirators are suitable, select an appropriatecombination of mask and filter. Select a filter suitable for combined particulate/organic gases and vapours [boiling point>65°C(149 °F)].

Hand Protection : 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 providesuitable chemical protection: PVC, neoprene or nitrile rubber

gloves. Suitability and durability of a glove is dependent onusage, e.g. frequency and duration of contact, chemicalresistance of glove material, glove thickness, dexterity. Alwaysseek advice from glove suppliers. Contaminated gloves shouldbe replaced. Personal hygiene is a key element of effectivehand 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.

Eye Protection : Wear safety glasses or full face shield if splashes are likely tooccur.

Protective Clothing : Skin protection not ordinarily required beyond standard issuework clothes.

Monitoring Methods : Monitoring of the concentration of substances in the breathing

zone of workers or in the general workplace may be required toconfirm compliance with an OEL and adequacy of exposurecontrols. For some substances biological monitoring may alsobe appropriate.

Environmental ExposureControls

: Minimise release to the environment. An environmentalassessment must be made to ensure compliance with localenvironmental legislation.

9. PHYSICAL AND CHEMICAL PROPERTIES Appearance : Clear pale yellow. Liquid at room temperature. Odour : Slight hydrocarbon.pH : Not applicable.

Initial Boiling Point andBoiling Range

: > 280 °C / 536 °F estimated value(s)

Pour point : Typical 0 °C / 32 °F Flash point : Typical 218 °C / 424 °F (COC) Upper / lower Flammabilityor Explosion limits

: Typical 1 - 10 %(V) (based on mineral oil)

Auto-ignition temperature : > 320 °C / 608 °F Vapour pressure : < 0.5 Pa at 20 °C / 68 °F (estimated value(s)) Specific gravity : Typical 0.88 Density : Typical 7.49 g/cm3 Water solubility : Negligible. n-octanol/water partitioncoefficient (log Pow)

: > 6 (based on information on similar products)

Kinematic viscosity : Typical 100 mm2/s at 40 °C / 104 °F

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Vapour density (air=1) : > 1 (estimated value(s)) Evaporation rate (nBuAc=1) : Data not available

10. STABILITY AND REACTIVITY Stability : Stable.Conditions to Avoid : Extremes of temperature and direct sunlight. Materials to Avoid : Strong oxidising agents. Hazardous DecompositionProducts

: Hazardous decomposition products are not expected to formduring normal storage.

Hazardous Polymerisation : Data not available Sensitivity to Mechanical

Impact

: Data not available

Sensitivity to StaticDischarge

: Data not available

11. TOXICOLOGICAL INFORMATION Basis for Assessment : Information given is based on data on the components and the

toxicology of similar products.Acute Oral Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg Acute Dermal Toxicity : Expected to be of low toxicity: LD50 > 5000 mg/kg Acute Inhalation Toxicity : Not considered to be an inhalation hazard under normal

conditions of use. Skin Irritation : Expected to be slightly irritating.

Eye Irritation : Expected to be slightly irritating.Respiratory Irritation : Inhalation of vapours or mists may cause irritation. Sensitisation : Not expected to be a skin sensitiser. Repeated Dose Toxicity : Not expected to be a hazard. Mutagenicity : Not considered a mutagenic hazard. Carcinogenicity : Product contains mineral oils of types shown to be non-

carcinogenic in animal skin-painting studies. Highly refinedmineral oils are not classified as carcinogenic by theInternational Agency for Research on Cancer (IARC). Other components are not known to be associated with carcinogeniceffects.

Reproductive and

Developmental Toxicity

: Not expected to be a hazard.

Additional Information : Used oils may contain harmful impurities that haveaccumulated during use. The concentration of such impuritieswill depend on use and they may present risks to health andthe environment on disposal. ALL used oil should be handledwith caution and skin contact avoided as far as possible.

12. ECOLOGICAL INFORMATION Ecotoxicological data have not been determined specifically for this product. Information given isbased on a knowledge of the components and the ecotoxicology of similar products.

Acute Toxicity : Poorly soluble mixture. May cause physical fouling of aquaticorganisms. Expected to be practically non toxic: LL/EL/IL50 >

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100 mg/l (to aquatic organisms) (LL/EL50 expressed as thenominal amount of product required to prepare aqueous testextract). Mineral oil is not expected to cause any chroniceffects 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 bemobile.

Persistence/degradability : Expected to be not readily biodegradable. Major constituentsare expected to be inherently biodegradable, but the productcontains components that may persist in the environment.

Bioaccumulation : Contains components with the potential to bioaccumulate.

Other Adverse Effects : Product is a mixture of non-volatile components, which are notexpected to be released to air in any significant quantities. Notexpected to have ozone depletion potential, photochemicalozone creation potential or global warming potential.

13. DISPOSAL CONSIDERATIONS Material Disposal : Recover or recycle if possible. It is the responsibility of the

waste generator to determine the toxicity and physicalproperties of the material generated to determine the proper waste classification and disposal methods in compliance withapplicable regulations. Do not dispose into the environment, indrains or in water courses.

Container Disposal : Dispose in accordance with prevailing regulations, preferablyto a recognised collector or contractor. The competence of thecollector or contractor should be established beforehand.

Local Legislation : Disposal should be in accordance with applicable regional,national, and local laws and regulations.


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 thismaterial.

Federal Regulatory Status

Notification Status

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EINECS All components listed.TSCA All components listed.DSL 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)

: 0, 1, 0

MSDS Version Number : 7.1

MSDS Effective Date : 01/06/2009

MSDS Revisions : A vertical bar (|) in the left margin indicates an amendmentfrom the previous version.

MSDS Regulation : The content and format of this MSDS is in accordance with theOSHA Hazard Communication Standard, 29 CFR 1910.1200.

MSDS Distribution : The information in this document should be made available toall who may handle the product.

Disclaimer : The information contained herein is based on our currentknowledge of the underlying data and is intended to describe

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