#3108P I Manual

8/11/2019 #3108P I Manual

1/38

#7030 SFP/DFP Rev. B 040330 CoolJet Operation Manual

1

High Pressure Coolant System

CoolJCoolJCoolJCoolJCoolJ et Systemset Systemset Systemset Systemset Systems 2900-A Saturn StreetBrea, CA USA 92821-6203

Phone (714) 577-9262 Fax (714) 577-9271Email [email protected] [email protected] [email protected]

Web www.cooljet.com

OperationManual

8/11/2019 #3108P I Manual

2/38

8/11/2019 #3108P I Manual

3/38


3

Table of Contents

Notice & Safety Precautions -----------------------------------------------------------------------2

Introduction ------------------------------------------------------------------------------------------4

Contents & Specifications of The CoolJet System ----------------------------------------------5

Installing The CoolJet System

Overview of System Operation -----------------------------------------------------------6

Mechanical Installation --------------------------------------------------------------------7

Electrical Installation----------------------------------------------------------------------- 9

Operating The CoolJet System

Startup Procedures - SF Models -------------------------------------------------------- 12Startup Procedures - DF Models-------------------------------------------------------- 13

Pressure Calibration Procedures -------------------------------------------------------- 14

CoolJet Controller and System Indicators --------------------------------------------- 15

Optimizing The CoolJet System

Pressure & Orifice Sizing --------------------------------------------------------------- 15

Maintaining The CoolJet System

Filter Replacement - SF Models -------------------------------------------------------- 17

Filter Replacement - DF Models ------------------------------------------------------- 18

Routine Maintenance--------------------------------------------------------------------- 20

Troubleshooting--------------------------------------------------------------------------- 22

Repair Instructions ----------------------------------------------------------------------- 24

Spare Parts --------------------------------------------------------------------------------- 31

Appendix A: Electrical Documentation ------------------------------------------------------ 37

Warranty -------------------------------------------------------------------------------------------- 38

Space for Notes ------------------------------------------------------------------------------------ 39

8/11/2019 #3108P I Manual

4/38

8/11/2019 #3108P I Manual

5/38

8/11/2019 #3108P I Manual

6/38


6

System Considerations:Safety Valve: CoolJet systems generate pressure by positive displacement. A High Pressure Regu-lator Valve is provided as a safety valve, to control the maximum system pressure and to preventover pressurization. Incorrectly adjusting the regulator setting may void warranty and could resultin personal injury or damage to the pump or your machine tool. Do not remove the High PressureRegulator valve from your system.

The Manufacturer does not assume any liability or responsibility for the misuse of a customers high-pressure system.

Pump Lubrication: Change oil after first 50 - 100 hours of operation and every 500 hours there-after. Fill crankcase with approximately 35 oz. (1.03 liters) of 15w-50 full synthetic motor oil.Refer to the section on changing the pump oil for details. DO NOT RUN PUMP WITHOUT OILIN THE CRANKCASE.

Inlet Pressure: A positive head pressure must be maintained to avoid problems associated withcavitation. In so doing, a dedicated supply pump is required to feed coolant to the 70-30 filter inlet.The supply pumps pressure capability should be determined prior to its installation. The CoolJetsystem has a system inlet pressure rating of 60 psi (4.1 Bar) maximum.

For supply pumps that provide excessive inlet pressure, CoolJet offers the #2503 Inlet PressureReducing Kit for regulating to 60 psi (4.1 Bar).

Filtration: The CoolJet requires coolant be filtered to a minimum of 500-micron. High capacityfilter bag elements rated at 100, 25, 10 or 5-micron are available from our factory. Pleated cartridgeelements are also available and are rated at 50, 25 or 10-micron.

Coolant Viscosity: The CoolJet system may be used to pump coolants or oils of viscosity up to 500SUS.

Considerations before InstallationA. Before installing the CoolJet system, verify that your entire coolant delivery system (hoses,

valves, fittings, coolant couplings) is capable of supporting your desired operating pressure.B. For best results, replace contaminated coolant and clean out machine reservoir to remove accu-

mulated chips and debris.C. Your CoolJet uses both tapered pipe (NPT) fittings and 37 o JIC hydraulic fittings. The JIC

fittings are designed to seal against pressure and vacuum leaks without the use of any pipe

sealant compound. For threaded NPT connections, use curing pipe thread sealant (such as Loctite#565) or PTFE liquid/tape. If tape is used, do not wrap beyond the last thread to avoid tape from

being lodged within the system.D. If you have any questions or require factory assistance during installation, please con-

tact CoolJet Customer Service.

8/11/2019 #3108P I Manual

7/38


7

The CoolJet system should be located to minimize the required hose lengths between theCoolJets pump and your machine. Verify the CoolJet interface cable length is adequate toreach machine tools electrical cabinet.

Position the pump assembly to provide adequate work space and allow room for checking

the oil level, changing oil, inspecting pressure gauges, and servicing filters.

Installing The CoolJet SystemLocating The Pumping System

INLET PLUMBING It is highly desirable to avoid creating turbulence when pumping coolants, please pay particular atten-

tion to the following when connecting an inlet line. Do not use inlet hoses or components (valves, fittings, etc.) smaller than 1.5 (38mm) I.D. If elbows are required in the inlet plumbing, 45 fittings are preferred to 90 fittings. Try to arrange

sweeping hose curves if 90 hose routings are required. Use thread sealant on any NPT fittings in the inlet plumbing. Any leaking joints can allow air to be

drawn into the system and cause cavitation. Sealant is not required for JIC 37 fittings. Mount the Low Pressure Plumbing as follows; the pipe support clamp should be fastened to the top of

the machines coolant reservoir. A check valve is used to maintain fluid prime to the transfer pump. Connect one end of the 1.5 (38 mm) diameter hose to the support clamp assembly. The other end

should be connected to the CoolJet coolant inlet. Make sure all hose clamps are tight.

8/11/2019 #3108P I Manual

8/38


8

Operator Warning LabelAffix the MACHINE WARNING LABEL to your ma-chine, preferably at eye level on the door of the ma-chine, providing maximum visibility to operators.

After completing the installation instructions, you will be ready to start up your CoolJet System. Beforecontinuing, be sure you have read the PrecautionsSection.

Installing The CoolJet System

High Pressure Hose GuidelinesUse at least 3 ft. of flexible hose between the CoolJets high pressure Discharge Fitting and any fixed connection or rigid piping at the machine. This is a protective measure to reduce vibration in the machinescoolant plumbing. A Pulsation Dampening Assembly is available to further minimize any adverse effectscaused by high pressure pulsations.If the machines coolant hoses are not rated for a minimum working pressure of 1250 psi (90 Bar) (8.6 MPa)they should be replaced. Select hose which meets the pressure requirements of the system (1250 psi mini-mum working pressure). Recommended discharge hose size is 3/4 (19mm) I.D. Line size should not besmaller than 1/2 (12.7 mm) I.D. Consult the factory for use of smaller discharge line sizes.

The Discharge Fitting is a 3/4 (-12) 37 o, JIC male hydraulic fitting.

CAUTION: Never install shutoff valves in the bypass line or between the pump and Regulating Valve.

! WARNINGThis machine is equipped with aHigh Pressure Coolant System.

DO NOT operate without properguards in place.

Read and understand Cool Jetinstruction manual before use.Improper use may cause bodily

Pressure Regulating ValveInstall the Bypass Pressure Regulating Valveand Discharge Tee Fitting on the CoolantOutlet Fitting from the pump (see diagram).As shown, the Bypass Regulating Valve should

be oriented to the side opposite the Oil LevelSite Gauge.

CAUTION: Never connect a high pressurehose directly to the Pump Discharge Fittingwithout the Discharge Tee Fitting and theBypass Pressure Regulating Valve.

Install the Discharge Pressure Gauge in thetapped port of the Discharge Tee Fitting. In-stall the 1/4 NPT plug in the unused port of theDischarge Tee Fitting . Use pipe sealant on the

gauge and plug threads.

Route the Bypass Hose to the coolant tank, asfar as possible from the Supply Pump inlet (toreduce the chance of turbulence and cavitation).The Bypass Hose should be secured at the cool-ant tank end to prevent the hose from beingejected from the tank.

TOP VIEW

CoolantOutletFitting

Pressure

(return to sump)Bypass Hose

Bypass PressureRegulating Valve

Fitting

Discharge

Plug

A Properly Rated High Pressure Discharge Hose

Discharge

GaugePressure

JIC DischargeFitting

Tee

AdjustingBolt

8/11/2019 #3108P I Manual

9/38


9

Installing The CoolJet SystemE l e c t r i c a l I n s t a l l a t i o n

Caution: This procedure should be performed by a qualified electrical technician.

WARNING! BE SURE THE POWER SUPPLY IS SWITCHED OFF BEFORE WORKING ON UNIT

Important DUTY CYCLE note: Before installing the CoolJet system, consideration should be givento the Start/Stop control method for the pump motor. Rapid on/off cycling of the motor can cause

premature damage and failure of the motor or contactor due to excess heat generation. If the customersDuty Cycle requires Start/Stop of the CoolJet more frequently than 4 times per minute, then CoolJetSystems requires an alternate control method to start the Cool Jet pump motor with one control signaland use another signal to a high pressure bypass valve for controlling high pressure to your machine.

POWER CONNECTIONThe CoolJet unit is shipped from the factory wired for Low Voltage operation (60HZ 208-230 / 50HZ190). If the operating voltage needs to be changed, the electrical controller would require some modi-

fications. Motor rotational direction is optional. The CoolJet pump performance is identical for either rotational direction. The unit must be properly grounded.

For reference: the motor connection configurations are shown below for a Low Voltage (standard) or High Voltage connection.

9

3

8

2

7

1 13

Low-Voltage (208-230)

LINE LINE

6 5 4

789

6 5 4

High-Voltage (440-480)

2

Three Phase

ELECTRICAL CONFIGURATION AND CONTROL CONNECTIONThe electrical installation will include the following steps:

A. Install the proper Control Relays for your machine and installation type

B. Install and connect the machine-side receptacles

8/11/2019 #3108P I Manual

10/38


10

Important Duty Cycle Note: Before installing the CoolJet system, consideration should be given to the Start/Stop control method for the pump motor. Rapid on/off cycling of themotor can cause premature damage and failure of the motor and / or contactor due toexcess heat generation .

If short high pressure cycles are required (i.e., several starts and stops within a few minute time span), thenit may be preferred to start the CoolJet pump motor with one control signal and use another signal to ahigh pressure bypass valve for controlling high pressure to your machine.

Warning: Connect only the power specified on the data label nameplate located in theCoolJet Electrical Control Cabinet.

WARNING!BE SURE THE POWER SUPPLY IS SWITCHED OFF

BEFORE WORKING ON UNIT

Caution: This procedure should be performed by a qualified electrical technician.

MACHINE SIDE RECEPTACLE (#4405) The standard CoolJet includes a DIN-connector interface and mating machine-side receptacles.

This interface makes future disconnect/reconnect very convenient and allows for easy movement of the CoolJet between machines.

Refer to the supplied CoolJet interface diagram for machine wiring instructions. Leave CoolJet receptacle unplugged or turned off during installation and setup.

Installing The CoolJet SystemE le c t r i c a l I n s t a l l a t i o n

8/11/2019 #3108P I Manual

11/38


11

Installing The CoolJet SystemE l e c t r i c a l I n s t a l l a t i o n

Install interface relays, RL1 and RL2 (for optional High/Low Pressure)The Standard CoolJet includes both 24vdc and 100-120vac relays. Verify your machines output signalvoltages and install the proper relays in the CoolJet electrical panel.

Checking the Transfer Pump rotation - (to be performed by Qualified Electrical Service personnel)

1. Momentarily toggle the Fill switch on the CoolJet control panel. Verify pump fan rotation matches therotation arrow on the pump.

Transfer pump motor must be checked for proper rotation. Failure to comply maydamage the pump and void the warranty. DO NOT RUN DRY.

8/11/2019 #3108P I Manual

12/38


12

P r io r t o I n i t i a l S t a r t u p Review the electrical installation instructions in the appendix. Verify that a Filter Element has been installed into the Filter Vessel. Insert the o-ring and wire filter hold-down into the Filter Vessel, ensuring they have seated

properly, then tighten down securely the Filter Vessel lids. Ensure that all hose fittings are tight. Ensure the oil level in the pump reservoir is within the acceptable range as viewed on the Oil

Level Site Glass.

Installing The CoolJet System - SF Models

DisconnectSwitch

Cool Jet ONIndicator Light

Air Purge Valve

Differential

Pressure Switch

Filter Drain Valve

Bypass Hose

Filter Drain Hose(return to sump)

(return to sump)

Cool JetController

Filter Inlet

Filter Outlet Gauge

Air Purge Valve

Air Purge/Drain Hose

Gauge

RearView

S i d eView

Wire Filter Hold Down

PROCEDURE FOR PURGING AIR FROM FILTER CANISTER1. Open Air Purge Valve , located at the top backside of the filter canister.2. Filter Drain Valve should be closed - center spoke of the yellow handle should be vertical.3. Turn Cool Jet Controller Disconnect Switch to the ON position. Turn the Run / Reset / Fill Switch

to the FILL position and hold the switch in this position. Only the supply pump should be running at thistime.

4. Watch the clear Air Purge/Drain Hose until only coolant is being discharged. Release the Run / Reset / Fill Switch and Close the Air Purge Valve . Any air in the canister should have been displaced by coolantat this point. Check the entire system for signs of leakage.

NOTE: Pressure gauge pointer should be steady. A bouncing or fluctuating pointer may indicate an excessiveamount of air is entrained in the coolant supply to the Cool Jet. Opening the filters Air Purge Valve whilerunning may help.

8/11/2019 #3108P I Manual

13/38


13

P r io r t o I n i t i a l S t a r t u p Review the electrical installation instructions in the appendix. Verify that Filter Elements have been installed into the Filter Vessels. Insert the o-ring and wire filter hold-down into the Filter Vessel, ensuring they have seated

properly, then tighten down securely the Filter Vessel lids.

Ensure that all hose fittings are tight. Ensure the oil level in the pump reservoir is within the acceptable range as viewed on the Oil

Level Site Glass.

Installing The CoolJet System- DF Models

PROCEDURE FOR PURGING AIR FROM FILTER CANISTERS1. Open Air Purge Valves , located at the top backside of both canisters.2. Position Filter Inlet Selector Valve (yellow handle) at a 45 angle, allowing coolant flow into both filter

canisters. Position Filter Outlet Selector Valve vertically. Filter Drain Valves should be closed - center spoke of the yellow handle should be vertical.

3. Turn Cool Jet Controller Disconnect Switch to the ON position. Turn the Run / Reset / Fill Switchto the FILL position and hold the switch in this position. Only the supply pump should be running at thistime.

4. Watch the clear Air Purge/Drain Hoses until only coolant is being discharged. Release the Run / Reset / Fill Switch and Close both Air Purge Valves . Any air in the canisters should have been displaced bycoolant at this point. Check the entire system for signs of leakage.

5. Position both the Filter Inlet and Outlet Selector Valves (yellow handles), either vertically or horizontallyto operate either the right or left filter, respectively.

NOTE: Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an exces-sive amount of air is entrained in the coolant supply to the Cool Jet. Opening the active filters Air PurgeValve while running may help.NOTE: With both canisters completely purged of air, Filter Selector Valves can be switched while the CoolJet and supply pump are running without affecting pump or machine operation.

DisconnectSwitch

Cool Jet ON

Indicator Light

Air Purge Valve

DifferentialPressure Switch

Filter Drain Valves

Bypass Hose


(return to sump)

Cool JetController

Filter InletGauges

Filter OutletGauges

Air Purge Valves

Filter Inlet Selector Valve

Filter Outlet Selector Valve

Air Purge/Drain HoseAir Purge/Drain Hose

Side View Rear View


8/11/2019 #3108P I Manual

14/38


14

S TA RT-U P P R O C E D U R E 1. Verify coolant level in machine reservoir is at least 3/4 full.2. Turn on power to both the supply pump and the Cool Jet pump.3. A fully primed system will run smoothly and deliver steady flow. Check the inlet pressure. Inlet pres-

sure must not exceed 60 psi . If necessary, add a #2503 Inlet Pressure Reducing Valve.4. Listen for any erratic noise; look for unsteady flow.5. If the system has an air lock in the high pressure lines, the pump may fail to prime. Follow the instruc-

tions for Setting Pressure below to remove air that may be trapped in the pump manifold and high pressure lines.

System Startup

In the event you wish to run a pressure lower than 1000psi (70 Bar), follow the above steps to set the desired pressure level. It is impotant to understand that the optimum orifice size will increase for a lower system pressure.

If system pressure or flow seems inadequate, verify CoolJet performance by installation of calibrating orifice.

Note: The Discharge Pressure Gauge needle should steadily increase. If the gauge needle stops moving whilethe Adjustment Nut is being turned, this indicates a problem. Typically, this occurs when the minimum dis-charge orifice or nozzle in the system is larger than .097 ( 2.46mm), or cumulative discharge orifice areaexceeds .0074 in 2 (4.767mm 2).

The Pressure Regulating Valve is the system safety valve to prevent over-pressurization. Under nocircumstances should the setting be higher than 1000 PSI (70 Bar).

S e t t i n g P r e s s u r e / P r e s s u r e C a l i b r a t i o n P r o c e d u r e

Caution: The Cool Jet unit should not be run in production with the Calibrating Orifice installed; flowwill be over-restricted, and bypass to the coolant reservoir.

To Check the Regulator Set Point:1. Verify that the Cool Jet Disconnect Switch and

machine M code activation signal are OFF .2. Remove the Discharge Hose Fitting from the Dis-

charge Tee Fitting. Install the Calibrating Ori-fice supplied with your system (see Illustration).Reinstall the Discharge Hose Fitting .

3. Loosen the lockdown nut on the Pressure Adjust-ing Nut .

4. Turn the Pressure Adjusting Nut to the full coun-terclockwise position (3-4 turns) to decrease thespring tension. Do not remove the bolt.

5. Activate the Cool Jet System. Slowly turn thePressure Adjusting Nut clockwise to increase thesetting until the desired pressure is reached. Do

not exceed 1000 PSI (70 Bar) under any circum-stance! If the system does not run smoothly, prime

by turning the Pressure Adjusting Nut in and outa few times as it smooths out.

6. After adjusting the Pressure Regulating Valve,tighten the Lockdown Nut to secure setting.

7. De-activate the system and remove the Calibrat-ing Orifice. Store for later use.

DecreasePressure

IncreasePressure

Regulating ValveAdjustment

DischargePressure Gauge

PressureAdjusting Nut


Plug

Discharge TeeFitting

DischargeHoseFitting

CalibratingOrifice


8/11/2019 #3108P I Manual

15/38


15

Cool Jet Controller and System Indicators

MAIN POWER DISCONNECTCAUTION: Three Phase line voltage may

be live at the terminal strip while the Cool JetDisconnect is in the OFF position.

THERMAL ALARM Indicator LampIndicates that the Thermal Overload for theCool Jet motor assembly has tripped.Possible causes :Amperage setting of motor starter too low.Coolant pressure set too high.

Unbalance or problem with incoming power.Overstress of the motor due to short cycle start/stop.Faulty motor.Short circuit or faulty motor starter.Action :Press RESET ButtonWait 3 minutes and reset breaker inside CoolJet controller enclosure.Verify amperage setting and Coolant pressure.Verify incoming line voltage.If Alarm re-occurs, contact Cool Jet Customer Service at (714) 577-9262 for assistance.

RESET / FILL Switch

This button resets all alarm conditions. After verify-ing any alarm cause, TOGGLE this button to silencethe BEEPER and to reset the CoolJet controller toready mode.

ALARM BeeperThe Beeper indicates a CoolJet alarm condition. Seethe Indicator Lamps to identify the associated alarm.

Push RESET SWITCH to silence Beeper.

8/11/2019 #3108P I Manual

16/38

8/11/2019 #3108P I Manual

17/38


17

Air Purge Valve

Drain ValveAssembly

OutputGauge

InletGauge

Clean OutPlug

SafetyStrainer Gauge

Oil Drain Cap

Fitting

RemovableAccess

Panels


Discharge

Front View Rear View

Inlet fromSupply Pump Differential

Pressure Switch

ElectricalController

Filter Drain Hose

Air Purge/Drain Hose

Filter DrainValve Handle(Yellow)


System Notes: Filter replacement is required when the differential pressure across the filter element reaches10-14 psi/d (1.0 Bar). The Cool Jet Service Filter audible alarm will sound.

Note: A damaged or improperly installed filter element will clog the Safety Strainer Screen and cause differ-ential pressure between the Output Gauge on the filter canister and the Safety Strainer Gauge . If this occursremove the Clean Out Plug from the Safety Strainer , clean the screen and reassemble.

F il t e r Re p l a c e m e n t I n s t r u c t i o n s 1. OBSERVE SAFETY SHOP PROCEDURES.

TURN MACHINE POWER OFF.

2. Open Drain Valve . Open Air Purge Valve .3. After pressure is relieved from filter housing (Inlet

and Outlet Gauges should read zero), remove lid.

CONTENTS UNDER PRESSURECONTENTS UNDER PRESSURECONTENTS UNDER PRESSURECONTENTS UNDER PRESSURECONTENTS UNDER PRESSURE

WARNING!Relieve Pressure in accordance

with Manufacturers instructionsbefore opening Filter Vessel.FFFFFAILAILAILAILAIL UREUREUREUREURE TTTTTO DO SO MAO DO SO MAO DO SO MAO DO SO MAO DO SO MA Y RESULY RESULY RESULY RESULY RESUL TTTTTIN SERIOUS BODILIN SERIOUS BODILIN SERIOUS BODILIN SERIOUS BODILIN SERIOUS BODIL Y INJURY INJURY INJURY INJURY INJUR YYYYY.....

4. Allow coolant to drain through filter element and back to machine sump. A filter canister holds 9gallons(33.75liters). Avoid spillage; check sump level prior to draining canister.

5. Remove filter canister o-ring and wire filter hold down. Wipe inside of housing above filter element.Remove and discard dirty filter element. Verify metal strainer basket is seated properly. Insert new elementinto basket. Be sure element seal ring is properly seated all the way down into its counterbore). A snug,light press fit prevents dirty coolant from leaking around the filter element seal ring. Install filter canister o-ring, filter hold down and secure filter lid.

6. Close the Filter Drain Valve - center spoke of the yellow handle should be vertical.

7. If required, remove Clean Out Plug from Safety Strainer , clean screen and reassemble.8. Before running Cool Jet Pump, purge air from filter housing: A) Leave Air Purge Valve Open. Using the FILL Switch, start the Low Pressure pump. B) Watch the clear Air Purge Hose until only coolant is being discharged. Close the Air Purge Valve . Release the FILL switch . C) With Supply Pump and Cool Jet running, the filter Inlet Gauge should read between 20-60psi (1.4- 4.1Bar).

Note : Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an excessiveamount of air is entrained in the coolant supply to the Cool Jet Pump.

Filter Replacement - (SF Models)

8/11/2019 #3108P I Manual

18/38


18

Filter Replacement - (DF Models)

Air Purge Valve

Filter Drain

Air Purge Valve

Filter Inlet Selector Valve

Filter Outlet

Air Purge/Drain HoseAir Purge/Drain Hose

Selector ValveFilter Selector Valve Handles

OutputGauge

OutputGauge

InletGauge

InletGauge

Air Purge Valves (backside)

Clean OutPlug

SafetyStrainer Gauge

Inlet fromSupply Pump

ElectricalController

Drain ValveAssemblies

Filter

Valve Handles(Yellow)

(Green)

Front View Rear View System Notes: Filter replacement is required when the differential pressure across the filter element reaches 10-14 psi/d (1.0 Bar). The Cool Jet Service Filter audible alarm will sound. By maintaining proper filter maintenance sequencing,changing the filter element can be accomplished without any machine down time. With the inactive filter ready (i.e. newelement properly installed and canister full of coolant), the Filter Inlet and Outlet Selector Valves can be changed atanytime without alarm, allowing for machine operation during filter change.Note: A damaged or improperly installed filter element will clog the Safety Strainer Screen and cause differential pressure

between the Output Gauge on the filter canister and the Safety Strainer Gauge . If this occures remove the Clean OutPlug from the Safety Strainer , clean the screen and reassemble.

WARNING! CONTENTS UNDER PRESSURECONTENTS UNDER PRESSURECONTENTS UNDER PRESSURECONTENTS UNDER PRESSURECONTENTS UNDER PRESSURERelieve Pressure in accordancewith Manufacturers instructionsbefore opening Filter Vessel.FFFFFAILAILAILAILAIL UREUREUREUREURE TTTTT O DO SO MAO DO SO MAO DO SO MAO DO SO MAO DO SO MA YYYYYRESULRESULRESULRESULRESUL TTTTTIN SERIOUS BODILIN SERIOUS BODILIN SERIOUS BODILIN SERIOUS BODILIN SERIOUS BODIL Y INJURY INJURY INJURY INJURY INJUR YYYYY.....

To ready the inactive filter during a machiningcycle, the procedure is as follows:

3. Allow coolant to drain through filter element and back to machine sump. A filter canister holds 9 gallons(33.75liters). Avoid spillage; check sump level prior to draining canister(s).

4. Remove filter canister o-ring and wire filter hold down. Remove and discard dirty filter element. Verify metal strainer basket is seated properly. Insert new element into basket. Be sure element seal ring is properly seated all the way down into its counterbore (see filter cut away view page 22). A snug, light press fit prevents dirty coolant from leaking around the filter element seal ring. Install filter canister o-ring, filter hold down and secure filter lid.

5. Close the Filter Drain Valve - center spoke of the yellow handle should be vertical. Leave the Air Purge Valve open.6. Position the Filter Inlet Selector Valve at roughly a 45 angle; redirecting some coolant flow into the inactive filter.7. Watch the Filter Inlet Gauge on the active filter (if the inlet pressure is reduced too much , the pressure switch will activate the

Service Filter Alarm.) Adjust the position of the Filter Inlet Selector Valve to regulate flow without activating alarm.8. Watch the inactive filters clear Air Purge/Drain Hose until only coolant is being discharged. Close the Air Purge Valve.9. Reposition the Filter Inlet Selector Valve to its original position. The position of the Filter Outlet Selector Valve should be the same as

that of the Filter Inlet Selector Valve .Having completed the steps outlined above, the inactive filter is ready for use, and can be switched with the Cool Jet operating, withoutaffecting pump or machine operation.

Note: Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an excessive amount of air is entrained in the coolant supply to the Cool Jet Pump.

1. Open Drain Valve . Open Air Purge Valve .2. After pressure is relieved from filter housing (Inlet and Outlet

Gauges should read zero), remove lid.

8/11/2019 #3108P I Manual

19/38


19

Strainer Basket

Filter Element

Filter Vessel

C

D

E

Lid O-Ring

Element Hold-down

Lid

A BF

(Seal Ring)

F i l t e r R F i l t e r R F i l t e r R F i l t e r R F i l t e r R e m o e m o e m o e m o e m o v v v v v a l & R a l & R a l & R a l & R a l & R e e e e e p l a c e m e n t p l a c e m e n t p l a c e m e n t p l a c e m e n t p l a c e m e n t 1. Install Strainer Basket (A) into Filter Vessel (F).2. Install Filter Element (B) into Strainer Basket (A). Assure the Seal Ring at the top of the

Filter Element (B) is completely seated into the Filter Vessel (F) flange counterbore, asshown in the cut-away drawing.

3. Install Element Hold-down (C) as shown.4. Wipe chips and dirt from Lid O-Ring (D) and install it into the top flange of the Filter

Vesse l (F).5. Install Lid (E) and retain with the Filter Clamp Assembly (not shown).


Seal Ring of the Filter Element

< Flow

FilterVessel

FilterElement

Replacement Filter Elements: Ordering Information

Part No. Description Type of

Filter

Surface

Area2159 5 micron1088 10 micron1089 25 micron1090 100 micron

Bag Element 4.4 ft2

(0.4 m 2)

S t r a

i n e r

B a s

k e

t

8/11/2019 #3108P I Manual

20/38


20

Maintaining the CoolJet System

DA I LY C H E C K S Check the filter inlet pressure gauge. The CoolJet has a system inlet pressure rating of 60 psi (4.1 Bar)maximum. A higher inlet coolant supply pressure must be regulated to ensure the safe operation of the CoolJet.

Oil Drain Cap

Oil Level

Oil Level

JIC Discharge

DischargePressure Gauge


Drain Valve


Bypass Fitting

Fitting

Site Glass

Fill Line

RemovableAccessPanel

PressureAdjusting Bolt


Maximum Oil LevelMinimum Oil Level

Oil Drain Cap(78)

Check the oil level and the condition of the oil. An oil level site glass has been mounted to theenclosure permitting a quick visual verification of the condition and oil level. An acceptable oil levelis between the two indicator lines on the oil level site glass.

CAUTION: If you are losing oil from the pump reservoir, but dont see any external leakage, or if the oil becomes discolored and contaminated, one of the diaphragms (20) may be damaged. Do not operate the pump with a damaged diaphragm. Refer to P u m p R e p a i r : F lu i d E n d for diaphragm service.

CAUTION: Do not leave contaminated oil in the pump housing or leave the housing empty. Removecontaminated oil as soon as discovered, and replace it with clean oil.

P E R I O D I C C H E C K S

Visually check the condition of the components in the high pressure coolant circuit. Any worn or damaged hoses should be replaced. Any leaking fittings should be tightened or replaced. Worn or damaged coolantnozzles can result in reduced system pressure.

Periodically inspect the discharge pressure gauge to verify that the CoolJet is operating at the desired pres-sure. Do not adjust the Pressure Regulating Valve without a proper orifice restriction ( .097 max.) at thecoolant outlet in your system. If required, use the 70-30 Calibrating Orifice and follow the pressure settinginstructions.

CAUTION: Never tighten down the pressure adjusting nut on the Regulating Valve without a properline restriction. This can result in an excessive pressure setting and damage your pumping system or machine. System warranty may also be voided.

Change the oil after the first 50-100 hours of operation and every 500 operating hours thereafter. Whenchanging, remove the oil drain cap (78) located on the side of the pump enclosure under the oil level siteglass allowing all the oil and accumulated sediment to drain out.

CAUTION: Do not turn the pump shaft (or motor fan) while the pump oil reservoir is empty. Thismay cause the need to disassemble the Pump Manifold (6) and Valve Plate (16) in order to prime thehydraulic cells in the Hydraulic End.

8/11/2019 #3108P I Manual

21/38


21

P u m p O i l M a i n t e n a n c e : C h e c k L e v e l D a i ly Check the oil level and the condition of the oil. The oil level should be 1 in. from the top of the fill

port or to the line on the oil fil l plugs dipstick. For added convenience, an oi l level site glass has beenmounted to the enclosure permitting a quick visual verification of the condition and oil level. Anacceptable oil level is between the two indicator lines on the oil level site glass.

CAUTION: If you are losing oil from the pump reservoir, but dont see any external leakage, or if the oil becomes discolored and contaminated, one of the pump diaphragms may be damaged. Do not operate the pump with a damaged diaphragm. Consult CoolJet Service.

P u m p O i l D r a i n i n g - S e e C AU T I O N N o t e Change the oil after the first 50 hours of operation and every 500 operating hours thereafter. Place the drain

pan (provided) under the oil level site glass, under the Oil Drain Cap. Remove the drain cap and allow oiland accumulated sediment to completely drain before replacing. When finished, secure the oil drain cap.Inspect the drained oil. Discolored oil or metal shavings in the oil may indicate the need for service of thewet end (valves and diaphragms) or hydraulic end (plungers, pistons, camshaft assembly) of the pump.

CAUTION: Do not drain the oil and leave the reservoir empty and do not turn the pump shaft (ormotor fan) while the pump oil reservoir is empty. This may cause the need to disassemble the PumpManifold and Valve Plate in order to prime the hydraulic cells in the Hydraulic End. Consult CoolJet Ser-vice for details.

P u m p O i l Re p l a c e m e n t Using the oil funnel provided with the CoolJet, insert the flexible extension down into the pumps oil fill

port. Refill the pump with approximately 35 ounces of 15w-50 full synthetic motor oil. The oil level should be to the fill line on the oil fill cap dipstick between the indicator lines on the oil level site glass, or approxi-mately 1 (25mm) from the top of the oil fill port.

C h a n g i n g T h e P u m p O i l


Maximum Oil Level

Oil Drain Cap

Minimum Oil Level

Change Oil Every500 hours

Refill WithMobile One(15W-50)

Full SyntheticMotor Oil

or equivalent

Capacity35 ounces

(1.03 Liters)

O i l

Access HolePry cap off

8/11/2019 #3108P I Manual

22/38


22

Troubleshooting AlarmsUnder normal operation, the CoolJet High Pressure System will be activated by the High Pressure m-code or the Manual control switch at the machine control. The CoolJet system will start and stop thehigh pressure and low pressure pumps as needed.

If the CoolJet System does not start , verify that the Electrical harness is properly connected and the

CoolJet Disconnect Switch is in the ON position. Also verify RESET - RUN- FILL switch in RUN position.

In the event of a CoolJet alarm , the CoolJet Alarm Beeper will sound.

Refer to the chart below for alarm indications.

Coolant Alarm - Low Coolant or Filter * Turn OFF the coolant command.(Alarm Beeper only) Toggle RESET switch to silence Beeper.

Possible Causes Resolution

Machine tool coolant level too low Verify and add coolantAir or turbulence at the feeder pump inlet Reposition return lines to sumpSump pump clogged with debris Remove debris/clean sumpCool Jet filter dirty Replace filter elementFilter Drain Valve open Close Filter Drain ValveCool Jet Safety Strainer clogged Clean Strainer Faulty Pressure Switch (#0371) Consult Cool Jet serviceFaulty Differential Pressure Switch (#2273) Consult Cool Jet service

Cool Jet service at (714) 577-9262 x111 ______________________________________________________________________________

Thermal Alarm - * Turn OFF the coolant command.(Alarm Beeper and Thermal Overload Lamp) Toggle RESET switch to silence Beeper.

Possible Causes ResolutionBreaker tripped Reset Breaker inside Cool Jet controller Incorrect amperage setting of Breaker Verify amperage settings per AppendixUnbalance or problem with incoming power. Verify incoming line voltage per nameplate.Coolant pressure too high (1000psi maximum) Check pressure / Re-calibrate pressureShort circuit or faulty motor starter Consult Cool Jet service at (714) 577-9262 x111Cool Jet motor faulty Consult Cool Jet serviceMotor stress due to short cycle start/stop. Consult Cool Jet service

8/11/2019 #3108P I Manual

23/38


23

If your pump is not performing properly, it will usually cause a change in coolant delivery at thetool or coolant nozzle (drop in pressure, pulsations, rough running, etc.). The most commoncauses of pumping problems can usually be found in the inlet lines to the pump. A clogged filter, low coolant tank levels, and air being drawn into the system through loose inlet fittings

prevent adequate supply to the pump inlet and can cause cavitation. Cavitation will cause a drop

in pumping performance; prolonged cavitation can damage the pump. The symptoms and typicalcauses of cavitation are listed below:

Drop in Volume or Pressure Cracked inlet hose Low coolant level in machine Excessive aeration and turbulence in coolant tank Coolant nozzle(s) have worn oversize Pressure Regulating Valve bypassing fluid to tank Worn pump valve parts Foreign material in pump inlet or outlet valves Loss of oil prime in cells because of low oil level Ruptured diaphragm Warped manifold from overpressurized system Pump O-rings forced out of their grooves from

overpressurization Cracked cylinder housing

Pulsating High Pressure Foreign object lodged in pump valve Loss of prime in hydraulic cells because of low oil level

in pump oil reservoir Air in suction line Valve spring broken Aeration or turbulence in coolant tank

Pump Runs Rough Worn pump valves Air lock in high pressure discharge lines Pump oil level low Air in inlet hose Restriction in inlet line Hydraulic cells not primed after changing

diaphragms Foreign material in inlet or outlet valves Damaged diaphragm Fatigued or broken valve spring Broken piston return spring

Coolant in Pump Oil Reservoir Ruptured diaphragm Hydraulic cells not properly primed after

diaphragm replacement Diaphragm screw O-ring missing or cracked Cracked cylinder housing

Loss of Oil from Pump Reservoir External seepage Rupture of diaphragm Diaphragm screw O-ring missing or cracked Worn shaft seals

Oil drain cap or fill cap loose Valve plate and manifold bolts loose

If you are experiencing pumping problems, the first step is to eliminate the possible problems regarding fluid supplyto the 70-30 pump inlet. Some of the problem symptoms and possible causes are listed below:

Symptoms of CavitationExcessive pump valve noisePremature failure of spring or retainer Premature failure of diaphragmsVolume or pressure dropRough-running pumpPiston return spring failure (inside hydraulic end)

Some Causes of Cavitation- Inlet line collapsed or clogged - Clogged line strainer or filter - Inlet hose too small or too long- Air leak in inlet line- Too many valves and elbows in inlet line- Air entrained in fluid piping system- Aeration and turbulence in supply tank

Troubleshooting the 70-30 Pump

General Rule of Thumb : If the problems remain, the 70-30 pump assembly may requireservice. With a few exceptions, the following rule of thumb regarding pump service will apply:1. Pumping problems accompanied by fluctuating/fluttering discharge pressure gauge needle

generally requires service of the Fluid End (Valves and/or Diaphragms).2. Problems accompanied by low pressure output with a steady gauge needle generally requires

service of the Hydraulic End.If you are going to service the 70-30 pump assembly, you may require a 70-30 Tool Kit availablefrom your CoolJet distributor. If you need assistance, contact CoolJet Customer Service.

8/11/2019 #3108P I Manual

24/38

8/11/2019 #3108P I Manual

25/38


25

Pump Repair: Fluid EndS e r v ic i n g t h e Va l ve s a n d D ia p h r a g m s

Va l v e We a r : Ca u s e s Normal wear over time.Cavitation.

Abrasive matter in the coolant.Valve incompatible with corrosives in the fluid.

Va l v e Sp r i n g / Re t a i n e r F a i l u r e : C a u s e s Cavitation.Foreign object in the pump.Spring/Retainer material incompatible with pumped fluid.Excessive (200 psi+) inlet pressure.

Installing Outlet Valves on Valve Plate

Correct

Incorrect :Retainer leg

pointing toward

3) Reinstall The Valve Assemblies:a) Clean the valve ports and shoulders with emery cloth;lubricate them with lubricating gel or petroleum jelly.

b) Install the O-ring (10) on the valve seat (11).c) Inlet Valves (3 center valves). Insert the spring retainer (15) into the valve plate, then insert the spring, valve and valve seat (11, 12, 13). The tetra seal (14) goes between theretainer and seat.d) Outlet (3 outer valves). Insert the valve seat, valve, and spring, then the retainer. Install the flat O-ring (14) betweenthe retainer and seat. Position the spring retainers (15) so aleg does not point toward the center of the pump (refer tothe illustration).

4) Inspect and Replace Diaphragms (20):a) Lift the diaphragm by one edge, and turn the pump shaftuntil the diaphragm pulls up. This will expose machined cross-holes in the plunger shaft behind the diaphragm.

b) Insert an Allen wrench through one of the holes, to hold the diaphragm up. The proper size tool is included in the70-30 Tool Kit.c) Remove the screw (17), O-ring (18), and follower (19) inthe center of the diaphragm.d) Remove the diaphragm, and inspect it carefully. A rup-

tured diaphragm generally indicates a pumping sys-tem problem, and replacing only the diaphragm willnot solve the larger problem. Inspect the diaphragmfor the following:

Half-moon marks: Usually caused by cavita-tion of the pump or excessive vacuum.

Concentric circular marks: Usually caused bycavitation of the pump.

Small puncture: Usually caused by a sharp chipor foreign object in the coolant.

Diaphragm pulled away: Usually caused byoverpressurization of the pump.

Slice in ridge of diaphragm: Occurs when adiaphragm is operated at cold temperatures.

Diaphragm edge chewed away: Usuallycaused by overpressurizing the system.

e) Inspect the plunger (21) for any rough surfaces or edges. Do not remove the plunger from the plunger shaft. Check for plunger rotation. Plunger should not rotate on shaft. Smooth the surfaces and edges asnecessary with emery cloth or a fine file.

CAUTION : If a diaphragm has ruptured and foreign material or water has entered the oil reservoir, do not operate the pump.Check all diaphragms, then flush the reser-voir completely (as outlined below) and re-

fill it with fresh oil. Never let the pump stand

with foreign material or water in the reser-voir, or with the reservoir empty.f) Install new diaphragm (or reinstall the old one, asappropriate), ridge side out.g) Clean the screw (17) and remove any oil from it.Apply medium-strength threadlocker to the screw.Reinstall the screw and follower (19), and a new O-ring (18). Tighten to 18lb-in (.20 meter-kgs).h) Repeat the above inspection procedure (and re-

placement, if necessary) with the other two diaphragms.

8/11/2019 #3108P I Manual

26/38


26

Priming the Pump Hydraulic Cells

During priming, oil and air will come out from

behind the 3 diaphragmedges. Continue turningthe shaft until only cleanoil comes out.

Diaphragms

Reinstalling Valve Plate10 OClock Position

Long screw (29) inthreaded hole.

4 OClock PositionShrot screw (25) in

threaded hole.

5) Flush Contaminate from Hydraulic End(only if a diaphragm has ruptured)a) Remove the oil drain hose assembly (34) and allowall oil and contaminate to drain out.

b) Fill the reservoir with kerosene or solvent, manuallyturn the pump shaft to circulate the kerosene, and drain.c) Repeat the flushing procedure (step b).d) Fill the reservoir with fresh oil, manually turn the

pump shaft to circulate the oil, and drain once again.e) Refill the reservoir with oil- Mobile One (15w-50) or equivalent. If the oil appears milky there is still contami-nate in the reservoir. Repeat the flushing procedure untilthe oil appears clean.

6) Prime the Hydraulic Cells

a) With the pump horizontal, fill the reservoir with oil-Mobile One (15w-50) or equivalent. b) All air in the oil within the hydraulic cell (behind thediaphragms) must be forced out by turning the shaft (and thus pumping the piston). A shaft rotator is included inthe 70-30 Tool Kit. Turn the shaft until a bubble-freeflow of oil comes from behind all the diaphragms. Watchthe oil level in the reservoir; if it gets too low during

priming, air will be drawn into the pistons (inside thehydraulic end) and will cause the pump to run rough.c) Wipe excess oil from the cylinder housing (24) and diaphragm.

Pump Repair: Fluid EndS e r v ic i n g t h e Va l ve s a n d D ia p h r a g m s

7) Reinstall Valve Plate (16) and Manifold (6) NOTE: Use the bolt (29) protruding through the cylinder casting at the 10 oclock position to locate the valve plate(16) on the cylinder housing (24). Place the blind holein the valve plate over this bolt.

a) Reinstall the valve plate (16), with the valve assembliesinstalled as outlined above, onto the cylinder housing (24).Recheck that the blind hole is over the protruding bolt at the10 oclock position.

b) Reinstall two capscrews (23) to secure the valve plate(16) to the cylinder housing (24). These screws lightly se-cure the plate to the housing to hold the diaphragms (20) in

place. Do not overtighten item (23) screws.c) Reinstall the O-rings (7, 8, 9) on the rear side of themanifold. Use O-ring lube or grease to hold them in place.

d) Reinstall the manifold onto the valve plate; be sure thedrain plug (3) is at the bottom of the manifold.e) Insert all bolts (4) around the edge of the manifold, and alternately tighten opposite bolts until all are secure. Torqueto 45 lb-ft (6.2 meter-kgs).f) Reinstall the centerbolt (1), with its washer (2) and tightenit. Torque to 45 lb-ft (6.2 meter-kgs).g) Recheck all bolts for tightness.

8/11/2019 #3108P I Manual

27/38


27

Pump Repair: Removal & ReplacementRegular maintenance of the 70-30 pump and some service can be performed with the pump head

bolted onto the motor. Replacement of the pump head and servicing of the hydraulic end generallyrequires removing the pump head from the motor. Follow the procedure below for removal and reassembly of the pump to the motor.

Note: Before proceeding, extra bolts may be required to assist in removing the pump from themotor. These extraction bolts should be 1/2-13 thread with a minimum 3 thread length.

Pump Head Reassembly1) Wipe the pump shaft clean and apply anti-seizelubricant to the shaft and keyway. Place key onthe pump shaft and apply more anti-seize to thekey. The pump is now ready to be placed onto themotor.2) Align keyway of the motor shaft with the pumpshaft. Slide pump head onto motor.

NOTE: Assure that the key does not get pushed all the way to the end of the key-way toward the

pump. Use a screwdriver during assembly to pushthe key into the motor shaft bore.3) Slide the pump head forward until the flangemates with the motor mounting face.4) Install the four bolts (38) and lockwashers (37)to secure the pump to the motor.

NOTE: It is important while tightening these boltsto support the weight of the pump head. This re-duces the weight load on the motor bearings dur-ing pump operation.5) Alternately torque the bolts in a cross patternto 55ft-lb (7.60 meter-kgs).6) Reinstall Pressure Switch Hose and Oil DrainHose.7) Reinstall the Pressure Regulating Valve and Inlet Hose assemblies (see Section III).8) Follow the start-up instructions previously cov-

ered in this manual.

Pump Head Removal1) Turn off main power at the machine.2) If your system has filter canisters, drainthe coolant from them.3) Disconnect and drain the Inlet Hose As-sembly and Pressure Regulating Valve Assem-

bly from the CoolJet Discharge Fitting.4) Remove Pressure Switch hose from

CoolJet inlet nipple.5) Remove oil drain hose from oil drain and cap outlet. Drain oil from Oil Site Glass, or the pump- whichever applies.6) Use a 3/4 wrench to remove the four 1/2-13 bolts (38) which secure the pump mount-ing flange to the motor face.7) With the bolts removed, the pump head should be free to rotate about the motor axis.The pump head might slide freely from thehollow motor shaft. Support the pump head and smoothly remove it from the motor shaft.8) If pump does not separate from motor, in-sert two extraction bolts (1/2-13 x 3 min.thread length) into the two threaded holes of the pump flange. Rotate the pump head onthe motor shaft to assure that the extraction

bolts do not damage the threaded holes in themotor mounting face.9) In small, even increments (one revolutionmax.), alternately tighten down the extraction

bolts. NOTE: Use care to assure that the pump trav-els straight and evenly away from the motor.The pump shaft may bend if this is done in-correctly.10) The pump head will slowly separatefrom the motor face. Continue tighteningthe extraction bolts until the pump may beremoved freely.

8/11/2019 #3108P I Manual

28/38

8/11/2019 #3108P I Manual

29/38


29

Pump Repair: Hydraulic End2) Remove Piston Assemblies (59)a) With the pump housing (30) removed, turn the cyl-inder housing (24) over and set it on a flat surface,

piston side down. b) With the diaphragms removed (covered earlier in

this manual), reinsert a follower screw (17) into thehole behind the plunger (21). Tap the screw lightlywith hammer: the plunger (21) should slip off the valve

plunger. The used plunger should be discarded.Contact CoolJet Systems or your local distributor toorder replacement parts.c) Repeat step b for the remaining pistons.

NOTE : When you reassemble the hydraulic piston,use new plungers (21). They are press-fit onto thevalve plungers and are not reusable.

3) Reassemble Pump Housing (30) and Hous-ing (24)

NOTE: Inspect the shaft seals (64) before continuing. If they look damaged in any way, replace them (re-move by tapping them out from inside the pump hous-ing). Both seals should be replaced at the same time.a) Place the cylinder housing (24) face-down on a flatsurface.

b) Insert the assembled pistons (50-59) into the cylin-der casting. The holes on the foot end of the pistonsshould all point toward the center of the casting.c) Note the location of the outer ring of holes in the

cylinder casting and the pump housing flange (in par-ticular, the holes where bolts (25) and (29) will beinstalled. Screw threaded studs (from the 70-30 ToolKit) into the two threaded holes at the 10 and 4 oclock

positions of the cylinder casting.d) Stand the camshaft assembly (62) on the cylinder casting (24).CAUTION: The pilot bearing MUST be properlynested in the bearing race during assembly. If mis-aligned, the bearing will be damaged and the pumpwill fail within a few hours of operation.e) Install the O-ring (65) and slide the housing (30)

down over the shaft and onto the threaded studs (fromstep c). Be sure the holes in the housing and the cylin-der casting are properly aligned.f) Install washer (5) and nuts (31) on the threaded studs, but dont tighten yet. You may want to inserttwo or more bolts (4) into the unthreaded holes of thehousing and cylinder casting to help align the parts.

g) Alternately tighten the nuts (31) to evenly drawthe housing down to the cylinder casting. Be surethe O-ring (65) stays in place.

NOTE: As you tighten the nuts, keep checking theshaft alignment by turning the shaft (use the rota-tor in the 70-30 Tool Kit). If the shaft begins tobind and become difficult to turn, back off the nutsand realign the shaft. When the housing is tight against the cylinder casting, you should be ableto turn the shaft smoothly.h) After the housing and casting are together, re-move the threaded stud at the 4 oclock positionof the housing and replace it with a bolt (25) and washer (5). Replace the threaded stud at the 10oclock position with a bolt (29) and washer (5).i) Turn the shaft again to check its alignment.

4) Replace Shaft Sealsa) Apply a thin film of grease on the seal protector tool (part of the 70-30 Tool Kit). Slide both sealsonto the tool, with the spring side of the seals to-ward the open end of the tool. Apply a heavier coat of grease between the seals and press themtogether.

b) Apply a coating of Locite High-PerformancePipe Sealant with Teflon , or a comparable prod-uct, to the outer surface of both seals and the in-side surface of the opening in the pump housingwhere the seals will rest.c) Apply a light film of grease to the drive shaft.Slide the seal protector tool (with the two seals)over the end of the shaft.d) Slide the seal insertion tool (from the 70-30Tool Kit) over the seal protector tool, and pressthe seals completely into place. Tap the tool witha soft mallet to firmly seat the seals.

8/11/2019 #3108P I Manual

30/38


30

Pump Repair: Hydraulic End5) Adjust Camshaft Endplaya) If the three set screws (22) are in the cylinder housing (24), remove and clean them.

b) Insert the centerbolt (1) into the hole in the center of the cylinder casting. Turn it in to move the bear-

ing adjusting plate (61) and cup tight against the bear-ing cone.c) Back out the centerbolt two full turns, then turn it

back in again until it is tight against the adjusting plate (61).d) Back out the centerbolt exactly 1/4 of a turn.e) With a plastic mallet (or a regular mallet or wooden

board) to prevent damage to the shaft, rap the end of the shaft 3 or 4 times. This will provide about .006endplay in the shaft.f) Apply removable threadlocker to the threads of the three cleaned set screws (22). Screw the three setscrews (22) into the cylinder casting until they con-tact the bearing adjusting plate (61).g) Remove the centerbolt (1).

6) Reinstall Plungers NOTE: If the plungers (21) have been removed fromthe valve plungers, do not reuse them. Install newones instead.a) Place a plunger on the exposed screw end of the

plunger guide tool from the 70-30 Tool Kit. The flatside of the plunger should face the tool.

b) Screw the guide (with the plunger) into the valve plunger until tight.c) Hold the single bottom handle of the guide, and turn the double top handle to force the plunger to seaton the valve plunger. This is a press fit when in-stalled, the plunger should be tight against the shoul-der of the valve plunger.

NOTE: Do not remove the plunger guide until thediaphragm is installed.d) Install the diaphragm as outlined below, then re-

peat the procedure for the other two plungers and diaphragms.

7) Reinstall Diaphragmsa) With the plunger guide tool still screwed into thevalve plunger (54), pull the valve plunger up until thecross-holes in the valve plunger are exposed.

b) Insert a diaphragm Allen wrench (from the 70-30Tool Kit), or similar dowel-type object, through the

holes to hold the plunger (21) away from the cylin-der casting, and to keep the valve plunger from turn-ing when the diaphragm is being installed.c) Place the diaphragm (20) onto the plunger (21),ridge-side out.

d) Center the diaphragm follower (19) on the diaphragm.e) Place the O-ring (18) onto the follower screw(17).f) Apply a small amount of threadlocker to thethreads of the follower screw.g) Insert the follower screw (with O-ring) throughthe diaphragm follower (19) and diaphragm (20),and screw it into the valve plunger (54).h) Hold the diaphragm Allen wrench, and tightenthe follower screw to 18 in-lbs. of torque.i) Repeat the above procedure for the plungers and diaphragms of the other two cylinders.

j) Fill the reservoir with fresh oil and prime thehydraulic cells, as outlined previously.

8) Reassemble Pump Heada) Reassemble the pump head as outlined previ-ously.

8/11/2019 #3108P I Manual

31/38


31

Replacement PartsP u m p U n i t

9495

100

108

113

115

116

117118

70

8887

8384

82

89

80

111

81

78

79101

112

77

90114

Item Part # Description Qty.

70 2176 Enclosure Assembly, 70-30 SF 1 77 1011 Inlet Nipple 1 78 2186 Oil Drain Cap, 1/4 NPT 1 79 0866 Plug (3/4 NPT) 180 2517 Assy, Pressure Regulating Valve 181 2516 Valve, Regulator, 1000 psi 182 0032 Hose, Bypass, 5/8 ID x 10 1

--- 0391 37 JIC Hose Barb 183 2515 Adapter Fitting, Regulator 184 0735 Bypass Elbow 187 0914 Calibrating Orifice (70-30 Series) 188 0869 Discharge Tee Fitting 189 0870 Gauge, Back Mount, 1500 psi 1

90 0843 Outlet Nipple 1 94 2134 Pump, 8GPM @ 1000PSI 195 0794 Motor 6/5 HP, 60/50 Hz 1

100 0223 Baseplate, Riser Assy, 70-30 1101 0993 Bolt, Motor Mount 4108 0857 Foot Assy 4


111 2187 Oil Drain Hose Assembly 1112 2182 Oil Level Site Gauge 1113 2181 Pressure Switch Hose Assembly 1114 2110 Pressure Switch Snubber 1115 0371 Pressure Switch 1116 1062 Pressure Switch Cable/din Assembly 1117 2199 Inlet Hose, 1 ID 1118 2197 Hose Clamp 1

--- 0975 70-30 Tool Kit (not included) --

--- 0095 Machine Warning Label 1

--- 2194 Oil Fill Funnel 1

--- 2195 Oil Drain Pan 1

8/11/2019 #3108P I Manual

32/38


32

Replacement PartsF il t r a t i o n C o m p o n e n t s - (S F M o d e l s )

120

121

Filter Vessel - Cut Away View

119


116 1062 Pressure Switch Cable/din Assembly 1117 2199 Inlet Hose, 1 ID 1119 2358 Filter Hold Down 1120 2355 Basket, Replacement - HCF 1121 2271 Filter Vessel, O-Ring 1122 2341 Clamp, Clamp Assy - HCF Lid 1123 0897 90 Elbow, 1MPT x 1 MJIC 1124 2205 Swivel Elbow, 1 JIC x 45 1


125 2273 Differential Press. Switch (10-14 psid) 1126 2472 Diff. Pressure Switch Cable Assy. 1127 2342 Screen, Strainer-60 mesh 1128 2150 Air Purge Valve 1130 2145 Drain Valve 1131 2317 Drain Hose, ID x 10 1

117

125

131

130

126

127

122

128

124

123

8/11/2019 #3108P I Manual

33/38


33

136

124

125

126

127

130

131

136

130

128

122

128

135

117

120

121

Filter Vessel - Cut Away View

119

Replacement PartsF il t r a t i o n C o m p o n e n t s - (D F M o d e l s )


117 2199 Inlet Hose, 1 ID 1

119 2358 Filter Hold Down 2120 2355 Basket, Replacement - HCF 2121 2271 Filter Vessel, O-Ring 2122 2341 Clamp, Clamp Assy - HCF Lid 2125 2273 Differential Press. Switch (10-14 psid) 1126 2472 Diff. Pressure Switch Cable Assy. 1


127 2342 Screen, Strainer-60 mesh 1

128 2150 Air Purge Valve 1130 2145 Drain Valve 2131 2317 Drain Hose, ID x 10 2135 2306 Controller Mount 1136 2200 Filter Selector Valve 2

8/11/2019 #3108P I Manual

34/38


34

Service and Repair Kits0975 70-30 Tool Kit2028 Fluid End Repair Kit

(includes: 7, 8, 9, 10, 11, 12, 13, 14, 15, 18, 20)2206 Diaphram Repair Kit, V-2

(includes 7, 8, 9, 18, 20)2030 Valve Repair Kit, Standard

(incl. 7, 8, 9, 10, 11, 12, 13, 14, 15)2031 Valve Repair Kit, Ceramic

(incl. 7, 8, 9, 10, 11*, 12*, 13, 14, 15)

ITEM PART # DESCRIPTION QTY 1 0951 Center Bolt 1 2 0987 Washer, 1/2, Flat 1 3 0952 Priming Plug 1 4 0988 Bolt, 3-1/2, Hex Head 6 5 0989 Lockwasher, 3/8 18 6 0520 Manifold 1 7 0772 O-ring, Center Bolt 1 8 2026 O-ring, Manifold, Inner 1

9 2027 O-ring, Manifold, Outer 110 0991 O-ring, Valve Seat 611 0953 Valve Seat 612 0954 Valve 613 0955 Valve Seat 614 0956 Tetra Seal 615 0957 Valve Spring Retainer 616 0958 Valve Plate 617 0982 Screw, follower 318 2024 O-ring, follower 319 0682 Follower 320 2207 Diaphragm, Viton 321 0961 Plunger 322 0983 Setscrew, Adjusting Plate 323 0984 Soc. Hd. Cap Screw 224 0962 Housing, Cylinder 125 0994 Capscrew, 3/8 x 7/8 long 126 0992 O-ring, Oil fill 127 0963 Oil fill cap (with breather) 129 0985 Capscrew, 3/8-16 x 1-1/8 130 0964 Housing, Pump 131 0986 Nut, 3/8-16, Hex 632 2202 Elbow, #6 MJIC x 1/8FPT 133 0879 Nipple, 1/8 x 4-1/2 137 0888 Lockwasher, 1/2 438 0887 Capscrew, 1/2-13 x 1-1/4 440 0966 Mounting Flange 141 0993 Capscrew, 3/8-16 x 3/4 442 2266 Gasket, cover 1

43 2267 Cover 144 0993 Screw, R.H. Mach, M4 x 12 - 4 445 0880 Elbow, 1/8 FPT 1

45

Replacement Parts7 0 -3 0 P u m p - F l u i d E n d

8/11/2019 #3108P I Manual

35/38


35

ITEM PART # DESCRIPTION QTY 21 0961 Plunger 3 24 0962 Cylinder Housing 1 59 0972 Piston Assembly 3 60 0997 O-ring, adjusting plate, viton 1 61 0973 Bearing Adjusting Plate 1 62 0974 Shaft/Cam Assembly 1

63 1184 Key, 3/16 x 1/4 x 1-3/4 1 64 0978 Seal, shaft 2 65 0979 O-ring, pump housing, viton 1

- 0975 70-30 Tool Kit -

Replacement Parts7 0 -3 0 P u m p - H y d r a u l ic E n d

8/11/2019 #3108P I Manual

36/38


36

Appendix A: Electrical Controller Schematic

21

23 T1.4

SCHEMATIC

B1 2

FAX:(714) 5779271

2900A SATURN STREET BREA CA 926216203

PHONE: (714)5779262

COOL JET SYSTEMS

TERMINAL CONN.WIRE NUMBERS

FIELD WIRING

( )

T1.2

T1.3

CR1.2

(RED)

(RED)

4

1

2

RL2

(RED)

(17)

CB1 2A(WHITE)

(10)

(N)

(10GA BLACK)

(10GA BLACK) (T11)

(S11)

MC1

L3

L2

T3

T2

460VAC, 11 AMPS

(10GA BLACK) (R11) L1 T1

TOTAL ALARMB

PRESSURE SWITCH

DELAY TIME "5 SEC"

THERMAL TRIP

H.P. MOTOR STARTER

(18)

PL1 YELLOW

CR1(WHITE)

T1

A1 A2MC1OL1

(N)

PUMP MOTOR

E

M1

COOL JET

RL1.1

PE

CR1.3

22

T1.4

27

26

CR1.4

ALARM RESET

ALARM COMMON

TOTAL ALARMN.C.(OPEN=ALARM)

COOLANT ALARMN.O.(CLOSE=ALARM)

THERMAL ALARMN.O.(CLOSE=ALARM)

12

(15)

(10)

(N)

(20)

N

(RED)

(RED)

(19)

#7030P-3557

4PDT

4PDT

CR1.1

6 HP

115 VAC

OL1

208-230VAC, 16.5 F.L.A.

M2

MC2

L2

L3 T3

T2

OL2

L1 T1PUMP MOTOR.75 HP208-230VAC, 2.4 F.L.A.

E

A2 A1 MC2

OL1

OL2

(N)

CB2 2A

150 VA

Z

Reset(MOM)

(MOM.)

RUN

Fill

208-23OVAC, 21 AMPSBCPD

460VAC, 8.8 F.L.A.

460VAC, 1.3 F.L.A.

(24vdc or 110vac)3RL1Z HPC "ON"

RL2.1 11

RL1.2

RL2.2

(WHITE)115 VAC

CR2

2PDT

CR2.1

LP

DP15

L.P. MOTOR STARTER

(12)

(11)

(15)

(N)

(13) (13)

J2

CR1.425 THERMAL ALARMN.C.(OPEN=ALARM)

OL2

(14)

(16)

CR2.2

10

32

30

31

29

RL2.2

RL1.2

AVAILABLE 12

AVAILABLE

11

10

9

(GRN/YEL)

(BLACK)

(BLACK)

(BLACK)

5

8

7

6

PE

#4331 POWER &CONTROL HARNESS

1

3

2

#3106P#3108P#3109P

(24vdc or 110vac)

LPC "ON"

8/11/2019 #3108P I Manual

37/38


37

CoolJet Customer Service may be reached in the U.S.A. at:Telephone } (714) 577-9262 Fax } (714) 577-9271

Email } [email protected] present your CoolJet serial number, machine tool type,

and the name of your distributor when you call or email.

MKT INNOVATIONS / COOL JET WARRANTY

What Is Covered: MKT Innovations warrants that the MKT product enclosed with this Limited Warranty statementwill conform to the manufacturers specifications and be free from defects in workmanship and material for a period of one year from the date of manufacturers shipment.

In Case of Warranty Problems: Should your MKT product prove defective during this period, you must promptly

notify your CoolJet Distributor. If required, MKT may request that you send the product securely packaged in itsoriginal container or an equivalent, along with proof of the date of purchase, to your CoolJet Distributor. MKT Innova-tions will, at its option, repair or replace on an exchange basis the defective unit, without charge for parts or labor.Postage, insurance and shipping costs incurred in presenting your MKT product for warranty or service are the usersresponsibility.

What This Warranty Does Not Cover: This warranty does not apply to defects caused by the fault or negligence of the buyer or third party, or should the product fail to be properly maintained, or fail to function properly as a result of misuse, improper installation, improper electrical current, improper shipping, damage caused by disasters such as fire,flood, and lighting, to defects reported to MKT after the warranty period has expired or to the normal wear of compo-nent parts of the product such as valves and seats, O-rings, diaphragms, springs, etc.

The warranty and remedy provided above are exclusive and in lieu of all other expressed warranties and unless stated herein, any statements or representations by any other person or firm are void. The duration of any implied warrantiesof merchantability or fitness of a particular purpose shall be limited to the duration of the express warranty set forthabove. Except as provided in this written warranty, neither MKT Innovations nor its affiliates shall be liable for any loss,inconvenience, or damage, including direct, special, incidental, or consequential damages, resulting from the use or inability to use the MKT product, whether resulting from breach of warranty or any other legal theory.

This Warranty is Subject to the Following Conditions:Specifications: Pump operations must be within discharge pressure and inlet pressure specifications. The pres-sure regulating valve must be correctly adjusted.

Pumped Fluids: The warranty is void if pump operation commences without sufficient fluid supplied to the pump. Do not run dry. Do not pump unfiltered cutting fluids or fluids incompatible with rubber seals. Contact CoolJet for additional information on questionable fluids.

Lubrication: The warranty is void if pump operation commences without oil in the crankcase. Use onlyCoolJet approved crankcase oil or equivalent.

Your CoolJet System is an important investment. MKT Innovations / CoolJet Systems is

dedicated to supporting that investment. Feel free to contact us.

8/11/2019 #3108P I Manual

38/38

Notes

Date post:	02-Jun-2018
Category:	Documents
Upload:	anotnio
View:	215 times
Download:	0 times

#3108P I Manual

Documents