AUTOLINE IITM ABRASIVE CUTTING HEAD

INSTALLATION AND MAINTENANCE PROCEDURES

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 CONFIDENTIALITY NOTICE
This document contains subject matter in which KMT Waterjet Systems has
proprietary rights. Recipients of this document shall not duplicate, use or
disclose information contained herein, in whole or in part, for other than the
purpose for which this manual was provided.

KMT Waterjet believes the information described in this manual to be accurate

and reliable. Much care has been taken in its preparation; however, the Company
cannot accept any responsibility, financial or otherwise, for any consequences
arising out of the use of this material. The information contained herein is
subject to change, and revisions may be issued advising of such changes and/or
additions.

KMT WATERJET SYSTEMS 2007

KMT Waterjet Systems

635 West 12th Street
PO Box 231
Baxter Springs, KS 66713-0231

Phone: (800) 826-9274

Fax: (620) 856-5050

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AUTOLINE IITM ABRASIVE CUTTING HEAD
INSTALLATION AND MAINTENANCE PROCEDURES

1. Overview
The Autoline IITM abrasive cutting head utilizes a quick connection mechanism and is designed to
be assembled with only one Allen wrench to loosen the setscrew and remove the abrasive wear
insert. It is the only cutting head in the industry with a precisely aligned diamond orifice. Every
Autoline IITM diamond orifice is pre-aligned before it leaves the factory.

Figure 1: Autoline IITM Abrasive Nozzle

• The nozzle cap provides a quick connection between the nozzle tube and the nozzle body.
The cap remains with the nozzle tube and includes an abrasive feed tube and handle.

• The removable nozzle body supports the abrasive wear insert, orifice and focusing tube.

• The diamond orifice converts high pressure water into a high velocity stream.

• The abrasive wear insert protects the body from excessive wear. Water and abrasive are
first combined in the wear insert.

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• The focusing tube entrains the abrasive into the waterjet and re-focuses the stream.

• The abrasive feed tube guides and connects the anti-static abrasive supply hose.

• The setscrew holds the wear insert in position.

• The T-knob holds and secures the focusing tube.

2. Installation
The Autoline IITM abrasive nozzle is shipped as a complete assembly. The orifice and focusing
tube are packaged separately and require installation.

1. Install the focusing tube in the nozzle body. Push the tube until it bottoms out on the wear
insert. Tighten the T-knob to secure the focusing tube.

2. Using the T-knob as a handle, rotate the removable body counter-clockwise 1/4 turn.

3. Slowly pull the body out of the nozzle cap.

Figure 2: Component Installation

4. Apply FML-2 grease to the o-rings on the wear insert and the nozzle body. Clean the top
of the wear insert where the orifice will be installed.

5. Apply a thin film of Pure Goop to all surfaces on the orifice except the top flat where the
jewel is located. Mount the orifice in the hole on the top of the wear insert.

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NOTE
Only KMT pre-aligned diamond orifices are recommended for use in the
Autoline IITM nozzle assembly. Standard sapphire or diamond orifices are not
aligned and will result in reduced cutting performance, asymmetric wear and
reduced focusing tube life.

Figure 3: Orifice Installation

Using your fingers, press down lightly and rotate the orifice clockwise and counter-
clockwise to evenly distribute the Pure Goop.

Failure to coat the contact surfaces of the orifice will result in damage to the orifice
and/or mating components.

6. Align the machined slot in the body with the locating pin on the nozzle cap and insert the
body into the cap. Push and rotate the body clockwise 1/4 turn to lock it in position.

The orifice sits loosely on the body. Make sure it remains in position during
installation.

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7. If necessary, install the abrasive feed tube in the nozzle cap, ensuring that the o-ring is
installed on the feed tube and the flats on the feed tube align with the flats in the cap.

Figure 4: Abrasive Feed Tube Installation

8. Thread the handle into the cap until it bottoms out. Make sure it is tightly retained.

Failure to tighten the handle completely may result in loss of vacuum causing
inefficient flow of abrasive into the wear insert.

9. Apply Pure Goop to the threads on the nozzle tube and thread the Autoline IITM assembly
onto the nozzle tube. This is a left-handed thread. Hand-tighten only, the components
will seal at 9 ft-lbs (12 Nm).

Over tightening can damage the cone surface of the orifice mount, the orifice and
the seating area on the nozzle tube.

10. Push-connect the plastic, abrasive supply hose (not included) onto the abrasive feed tube.

11. If the hose and feed tube/handle are not aligned in the desired direction, loosen the gland
on the pneumatic valve and rotate the nozzle tube and Autoline IITM assembly as one
component to the desired location. Tighten the gland to 50 ft-lbs (68 Nm).

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If the valve assembly is normally closed, air must be applied before the gland can
be loosen or tightened. Failure to do so will result in damage to the valve stem and
seat.

12. The Autoline IITM cutting head assembly can now be placed in service.

3. Service and Maintenance

The following procedures are recommended for servicing the Autoline IITM cutting head
assembly. Proper installation and maintenance will ensure the best cutting performance and
longer operating life for all wear components.

Focusing Tube Replacement

Replacement frequency of the focusing tube depends on cutting quality requirements. To

maintain productivity the bore diameter of the focusing tube should not be worn more than 30-
40% of the original diameter. For example, if the original diameter is 0.030” (0.76 mm), the bore
diameter must not exceed 0.042” (1.07 mm).

1. Loosen the T-knob and pull the focusing tube out. Use compressed air to remove any
abrasives or water inside the nozzle body.

2. Install a new focusing tube into the nozzle body.

3. Push the focusing tube until it bottoms out on the wear insert. Lightly push the tube into
the body with one hand, and hand-tighten the T-knob with the other hand. This will
ensure the top face of the focusing tube is seated firmly against the bottom face of the
wear insert.

Figure 5: Focusing Tube Replacement

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Diamond Orifice Replacement

If the abrasive water stream is inconsistent and ‘fanning’, either the focusing tube or the diamond
orifice needs to be replaced; or the orifice needs to be cleaned with an ultra-sonic cleaning device.

Only KMT pre-aligned diamond orifices are recommended for use in the Autoline IITM nozzle
assembly. Standard sapphire or diamond orifices are not aligned and will result in reduced
cutting performance, asymmetric wear and reduced focusing tube life.

1. Using the handle, rotate the nozzle cap 1/2 turn or more to loosen the orifice from the
nozzle tube seat. It may be necessary to remove the abrasive supply hose from the feed
tube.

Figure 6: Diamond Orifice Replacement

2. Using the T-knob as a handle, rotate the removable body counter-clockwise 1/4 turn.

3. Slowly pull the body out of the nozzle cap and remove the orifice.

The orifice sits loosely on the top of the wear insert. Carefully remove the body to
prevent the orifice from falling out. A small amount of Pure Goop applied to the
orifice seat will minimize the risk of this occurring.

4. Clean any abrasive particles from the outside of the body. Apply a thin film of Pure Goop
to all surfaces of a new orifice except the top flat surface where the jewel is located.
Install the new orifice.

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Failure to coat the contact surfaces of the orifice will result in damage to the orifice
and/or mating components.

5. Align the machined slot in the body with the locating pin in the nozzle cap and insert the
body into the nozzle cap.

6. Using the T-knob as a handle, rotate the body clockwise 1/4 turn.

7. Using the handle on the nozzle cap, hand-tighten the nozzle assembly onto the nozzle
tube. Hand-tighten only, the components will seal at 9 ft-lbs (12 Nm).

Over tightening can damage the cone surface of the orifice mount, the orifice and
the nozzle tube.

NOTE
If a new orifice and an old nozzle tube with a worn seating surface are used, much
higher torque may be required to seal the components. If the components do not
seal properly at the specified torque, replace the nozzle tube.

Wear Insert Replacement

If the cutting performance is not satisfactory, or if the small jet-passage hole in the top of the
abrasive wear insert enlarges to a star pattern, the wear insert needs to be replaced.

NOTE
A .030 (.763) wear insert should be used with 7/21, 10/30 and 12/36 nozzle
assemblies. Nozzle assemblies 13/40 and 14/43, require a .043 (1.09) wear insert.

1. Follow Steps 1-3 in the procedure, Diamond Orifice Replacement.

2. Use an Allen wrench to loosen the setscrew in the body and remove the wear insert.

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Figure 7: Wear Insert Replacement

3. Clean any abrasive particles from the nozzle body where the wear insert is seated. Failure
to do so may cause improper seating of the insert, resulting in a misaligned jet.

4. Install a new wear insert ensuring the insert is properly aligned with the setscrew.

5. Tighten the setscrew to a maximum of 20 in-lbs (2.3 Nm).

6. Clean the top face of the new wear insert. Apply Pure Goop to all surfaces of the orifice
except the top flat where the jewel is located. Install the orifice into the wear insert.

Failure to coat the contact surfaces of the orifice will result in damage to the orifice
and/or mating surfaces.

7. Follow Steps 5-7 in the procedure Diamond Orifice Replacement.

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4. Troubleshooting
The following troubleshooting guide will help identify the probable cause of a malfunction and
assist in providing corrective action.

Troubleshooting Guide

Malfunction Comments
1. Orifice drops out during Pull the body out very slowly, apply Pure Goop to all surfaces on
nozzle body removal the orifice except the top flat where the jewel is located and re-
install.

2. Orifice sticks tightly on the Sticking may be caused by over tightening the cutting head
nozzle tube after removal assembly. Hand-tighten only, 9 ft-lbs (12 Nm) maximum. Use
your finger to apply some pressure on the stem of the orifice to
loosen it from the nozzle tube. If it is too tight, use a small brass
or aluminum rod to tap the orifice mount down to release it from
the nozzle tube.

3. Water leaks back into the Check the focusing tube for blockage. If the focusing tube is
abrasive supply hose when plugged, isolate the abrasive supply from the cutting head, install
the high pressure water the tube in the opposite direction and attempt to purge with high
valve is on pressure water.

Check for contaminates in the garnet that could plug the focusing
tube.

Check the garnet for moisture. If the garnet is wet, replace with
dry garnet.

Check the abrasive feed tube and supply hose for moisture. If the
feed tube or hose is wet, air dry them, blow out the wet garnet and
test again for leakage.

Check for missing or fractured orifice.

Check for dripping or leakage from the nozzle tube and/or from
the focusing tube when the valve is closed. If leakage is observed,
replace the valve stem and seat.

Leaking water will wet the garnet and garnet entering the wear
insert in clumps will plug the focusing tube resulting in water
backing out from the abrasive feed tube.

Use the handle to tighten the nozzle cap on the nozzle tube. If
leakage is still observed from the weep hole, replace the nozzle
tube. The cone seating surface may be worn or damaged.

Check the distance between the focusing tube and the work piece
standoff. Generally, the distance should be at least 0.050” (1.27
mm), especially for piercing operations.

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Troubleshooting Guide

Malfunction Comments
4. Water leaks into the Check for dripping or leakage from the nozzle tube and/or from
abrasive supply hose when the focusing tube when the valve is closed. If leakage is observed,
the high pressure water replace the valve stem and seat.
valve is off
Leaking water will wet the garnet and garnet entering the wear
insert in clumps will plug the focusing tube resulting in water
backing out from the abrasive feed tube.

5. Abrasive water stream is Inspect the orifice for damage. Any abrasive particles or metal
bad, ‘fanning’ chips can damage the orifice.

Check the alignment by shutting the pump down with the high
pressure water valve on. This will produce a fish line-like stream
for the alignment inspection. Misalignment is characterized by
the stream hitting the wall of the focusing tube when exiting the
bore.

If damage or misalignment is detected, replace the orifice with a

pre-aligned, KMT diamond orifice only. Standard orifices, either
sapphire or diamond are not aligned and will result in reduced life
of the focusing tube.

Ensure the bottom face of the orifice mount and top face of the
wear insert is clear of grit or garnet that may cause the
misalignment of the jet.

Verify the top hole in the wear insert is the appropriate size for the
orifice and focusing tube selected. Refer to procedure, Wear
Insert Replacement. Using a smaller hole than specified will
result in the stream hitting the walls of the hole at the center of the
wear insert.

A collision between the cutting head and the work piece may
result in the deformation or permanent misalignment of critical
components. Check alignment and replace damaged components
if necessary.

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Troubleshooting Guide

Malfunction Comments
6. Asymmetric wear on the Verify the cutting head has been operating with pre-aligned, KMT
outlet of the focusing tube diamond orifice. Standard orifices, either sapphire or diamond are
not aligned and will result in reduced cutting performance and
asymmetric wear, reducing the life of the focusing tube.

Use of standard orifices, either sapphire or diamond are not

aligned and will result in asymmetric wear. Indexing the focusing
tube by 1/4 turn every 10 to 12 hours of operating time may
optimize focusing tube life by evenly distributing the wear around
the perimeter of the tube.

Use of standard, non-aligned orifices may still result in a drastic

reduction in the operating life of the wear insert.

A serious collision in the cutting table may result in the

deformation or permanent misalignment of critical components.
Check alignment and replace damaged components if necessary.

7. Focusing tube is clogged Isolate the abrasive supply from the cutting head, install the
focusing tube in the opposite direction and attempt to purge with
high pressure water.

Check the garnet for moisture. If the garnet is wet, replace with
dry garnet.

Check the abrasive feed tube and supply hose for moisture. If the
feed tube or hose is wet, air dry them, blow out the wet garnet and
test again for leakage.

Verify the garnet size is appropriate for the focusing tube size.

Check for contaminates in the garnet that could plug the focusing
tube.

Check for dripping or leakage from the nozzle tube and/or from
the focusing tube when the valve is closed. If leakage is observed,
replace the valve stem and seat.

Leaking water will wet the garnet and garnet entering the wear
insert in clumps will plug the focusing tube resulting in water
backing out from the abrasive feed tube.

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Troubleshooting Guide

Malfunction Comments
8. Nozzle body will not pull Loosen the nozzle cap 1/2 turn or more clockwise. Rotate the
out nozzle body 1/4 turn counter-clockwise to align the locating pin
on the nozzle cap with the machined slot in the nozzle body.
Wiggle and pull the body out. Inspect the o-rings and replace if
necessary.

Clean the abrasive from the nozzle cap and body before re-
installing.

9. Significant loss in cutting Check the process settings; pressure, abrasive type and flow rate,
speed orifice/focusing tube combination and material.

Check the alignment and replace the orifice with a KMT pre-
aligned diamond orifice if misalignment is observed.

If the nozzle is used in a misaligned state for a prolonged time, the

focusing tube may be damaged and require replacement.

Check for vacuum loss. Vacuum loss can occur between the
abrasive feed tube and the handle. Verify the handle is threaded
tightly into the nozzle cap. Replace the o-ring on the feed tube if
necessary.

Ensure the nozzle body is fully rotated 1/4 turn and locked into the
nozzle cap. If the abrasive feed tube and the abrasive inlet on the
wear insert are not properly aligned, an adequate amount of
abrasive will not enter the insert.

Check the o-ring on the wear insert and replace if damage or wear
are detected. A damaged o-ring will result in air being drawn in
through the weep hole, resulting in vacuum loss.

10. Fracturing glass or other Use a lower pressure for these applications, less than 20,000 psi
brittle materials when (1,379 bar).
piercing
When turning the jet on, program the ABRASIVE ON a half second
preceding the WATER ON. When turning the jet off, program the
WATER OFF a half second following the ABRASIVE OFF.

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Troubleshooting Guide

Malfunction Comments
11. Cutting water is exiting the Ensure the abrasive feeder mechanism is working and feeding the
focusing tube; however, it is correct amount of abrasive.
not cutting properly
Check the garnet for moisture. If the garnet is wet, replace with
Cutting water is exiting the dry garnet.
focusing tube; however,
abrasive is not being drawn Check the abrasive feed tube and supply hose for moisture. If the
into the mixing chamber. feed tube or hose is wet, air dry them, blow out the wet garnet and
test again for leakage.

Ensure the nozzle body is fully rotated 1/4 turn and locked into the
nozzle cap. If the abrasive feed tube and the abrasive inlet on the
wear insert are not properly aligned, an adequate amount of
abrasive will not enter the insert.

Check the o-ring on the wear insert and replace if damage or wear
are detected. A damaged o-ring will result in air being drawn in
through the weep hole, resulting in vacuum loss.

5. Specifications
Table 1 provides specifications and torque values for the for the Autoline IITM abrasive nozzle
assembly.

Table 1
Specifications

Maximum inlet high pressure water 60,000 psi (4,137 bar)

Weight, including focusing tube and guard 1.31 lb (596 g)

Torque Values
Hand tight, maximum 10 ft-lbs (13.6 Nm)
Setscrew, maximum 20 in-lbs (2.3 Nm)

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6. Parts List
This section contains a list of parts the Autoline IITM abrasive nozzle assembly. Assemblies are
available in five standard diamond orifice/focusing tube configurations as detailed in Table 2. 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 Spare Parts Department at KMT Waterjet Systems.

USA Europe
Customer Service Department Spare Parts Manager
KMT Waterjet Systems KMT Waterjet Systems GmbH
PO Box 231 Wasserstrahl Schneidetechnik
Baxter Springs, KS 66713-0231 Auf der Laukert 11
D-61231 Bad Nauheim
Germany

Phone (800) 826-9274 Phone +49-6032-997-119

Fax (620) 856-2242 Fax +49-6032-997-271
Email wj.parts@kmtgroup.com Email order.spares@kmt-waterjet.com

Table 2
Autoline IITM Abrasive Nozzle Assemblies

Part
Item Number Description Quantity

20454114 7/21 Assembly

1 20453949 Autoline IITM Nozzle Assembly, .030 wear insert 1
2 05063847 Diamond Orifice, .007 1
3 10139426 Focusing Tube, .021 x 2.007 1

20454117 10/30 Assembly

1 20453949 Autoline IITM Nozzle Assembly, .030 wear insert 1
2 05077029 Diamond Orifice, .010 1
3 10126969 Focusing Tube, .030 x 3.125 1

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Table 2
TM
Autoline II Abrasive Nozzle Assemblies

Part
Item Number Description Quantity

20454120 12/36 Assembly

1 20453949 Autoline IITM Nozzle Assembly, .030 wear insert 1
2 05077300 Diamond Orifice, .012 1
3 05116652 Focusing Tube, .036 x 3.125 1

20454123 13/40 Assembly

1 20454108 Autoline IITM Nozzle Assembly, .043 wear insert 1
2 05136098 Diamond Orifice, .013 1
3 49835390 Focusing Tube, .040 x 3.125 1

20454126 14/43 Assembly

1 20454108 Autoline IITM Nozzle Assembly, .043 wear insert 1
2 05077037 Diamond Orifice, .014 1
3 10126928 Focusing Tube, .043 x 3.125 1

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Table 3
TM
Autoline II Nozzle Assemby
20453949/20454108

Part
Item Number Description Quantity
1 20453952 Nozzle Cap 1
2 20453958 Nozzle Body 1
3 20453064 Wear Insert, .030 1
20453082 Wear Insert, .043
4 20453964 Abrasive Feed Tube Assembly 1
5 20453973 Handle 1
6 20433398 Setscrew, 8-32 1
7 20453976 T-Knob 1
8 05138821 O-Ring, .69 x .81 x .06 1
9 20445476 O-Ring, .31 x .44 x .06 1
10 05087168 Guard 1
11 05081518 O-Ring, .38 x .50 x .06 1
12 05077078 O-Ring, .38 x .50 x .06 1

49885361 Plastic Feed Hose

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Table 3
TM
Autoline II Nozzle Assemby
20453949/20454108

Part
Item Number Description Quantity

20454129 Spare Parts Kit

20433398 Setscrew, 8-32 2
05081518 O-Ring, .38 x .50 x .06 2
20445476 O-Ring, .31 x .44 x .06 3
05138821 O-Ring, .69 x .81 x .06 2
05077078 O-Ring, .38 x .50 x .06 2

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