m406 - en Mach 3b and 4b Series

MACH 3B SERIES
MACH 4B SERIES
Models:
M3-4020b, M3-3020b, M3-2513b, M3-7320b, M3-1313b
M4-4020b, M4-3020b, M4-2513b, M4-7320b, M4-1313b
M-406 | Rev. B | January 2010
Mach 3b and Mach 4b Series System

Operation & Service Manual
Due to continuing product improvement, the information contained in this document is subject to change without
notice. Flow International Corporation shall not be held liable for technical or editorial omissions made herein, nor for
any incidental or consequential damage resulting from the use of this material.
This document contains information protected by copyright. No part of this document shall be reproduced in any
manner without prior written consent from Flow International Corporation.
MACH3 and MACH4 are trademarks of Flow International Corporation.
PASER ECL Plus, Dynamic Waterjet, WaterVeyor, HyperJet, HyPlex Hybrid, FlowPATH, and FlowCUT are
registered trademarks of Flow International Corporation.
2009-2010 Flow International Corporation. All rights reserved.
2 | M-406
Flow International Corporation
Introduction

Chapter 1. Equipment Description & Operation
System components 7
Integrated ultrahigh-pressure pump 8
FlowMaster PC-based controller 8
WaterVeyor abrasive removal system 8
End effector 8
Abrasivejet system 8
Catcher tank 8
Light curtain safety device 8
Spray containment kit 8
System Specifications 9
Machine features 9
Options 9
Installation requirements 10
Environment 10
Oil requirements 10
Water requirements 11
Water interface connections 12
Drain requirements 13
High-pressure tubing 13
Startup procedures 14
Starting the Hyperjet 94i-S or 94i-D intensifier pump
after installation 14
Starting the 50i-S or 100i-D intensifier pump
after installation 17
Starting the HyPlex pump after installation 20
System operation 22
Fault indicators 22
Machine startup 22
Machine shutdown 22
Running the pump 23
HyperJet 94i-S or 100i-D pump 23
50i-S or 100i-D intensifier pump 23
HyPlex Hybrid pump 23
Using dual pressure 23
Changing low-pressure or high-pressure
setting (intensifier pump) 23
Warning and shutdown sensors 23
Calibrating the pump to a gauge 23
Chapter 2. Safety
Safety precautions 27
Warnings, cautions, and notes 27
Safety tips 27
Protective clothing 29
Emergency medical information 30
Chapter 3. 60K End Effectors

Standard end effector 31
Dynamic Waterjet end effector 31
Z-axis 32
Work envelope 32
Maintenance 32
DWJ wrist assembly 33
Maintenance 33
Wrist assembly exploded view 34
Mini on/off valve 35
Specifications 35
Maintenance 35
Troubleshooting the valve 36
Servicing the valve 41
High-precision cutting head 44
How it works 44
Chapter 4. 94K End Effector
Standard end effector 47
Dynamic Waterjet end effector 47
Z-axis 48
Work envelope 48
Maintenance 48
DWJ wrist assembly 49
Maintenance 49
On/off valve 50
Specifications 50
Maintenance 50
High-precision cutting head 51
How it works 51
Servicing the cutting head components 53
Control panel 24
M-406 | 3

Chapter 5. X,Y Table

X,Y table maintenance 55
Inspection 56
Recommended lubricants 57
Recommended cleaners 57
Troubleshooting the X,Y table 58
Chapter 6. Engineering Drawings
Pumps 61
Plumbing 62
End effectors 63
X,Y assemblies 64
Catchers 64
Electrical 65
Kits 66
Miscellaneous service parts 66
4 | M-406
Introduction
Introduction
The information in this manual will help you become familiar with your new Flow International (FLOW) equipment. It
was compiled from the most current information available at the time of publication and is intended to cover the
most common configurations.
Safety
All operating personnel and service technicians must read and follow the procedures in this manual to avoid creating
unsafe conditions, or risking damage to the equipment.
The comprehensive list of safety precautions in Chapter 2 must be followed to ensure safe operation of the equipment. These precautions must be reviewed and understood by operating and maintenance personnel before installing,
operating, or servicing the equipment. The high-pressure waterjet system is a powerful cutting tool and must always
be treated with respect.
Warnings, cautions, & notes

Before operating the equipment, please read, thoroughly understand, and follow all warnings, cautions, and notes that
appear in this manual. They are defined as follows:
WARNING
Highlights an operating or service procedure or condition that
can result in death or serious injury to personnel.
CAUTION
Highlights an operating or service procedure or condition that
can lead to impaired system operation or equipment damage.
Note: Highlights an operating or service procedure or condition that is essential for efficient operation and service.
M-406 | 5

Notes
6 | M-406
CHAPTER 1
Equipment Description & Operation

The Mach 3b and Mach 4b Series Systems are free-standing gantry shapecutting systems. This machine is electric AC
servomotor-driven and microprocessor-controlled from the FlowMaster PC-based controller.
M-406 | 7

System components
The Mach 3b and Mach 4b Series System includes the
following components.
FlowMaster PC-based controller
Integrated ultrahigh-pressure pump
WaterVeyor abrasive removal system
There are five available pumps for the Mach 3b and

Mach 4b Series System, described in these manuals:
The Waterveyor is designed to remove spent abrasive

and kerf material from the catcher tank.
50i-S or 100i-D intensifier pump

Refer to manual M-349, 50i-S Pump or M-351, 100i-D
pump.
HyPlex Hybrid pump

Refer to manual M-397, HyPlex Hybrid Pump.
HyperJet 94i-S or HyperJet 94i-D intensifier pump

Refer to manual M-390, HyperJet 94i-S & 94i-D Pump
Refer to the FlowMaster CD
Refer to manual M-357, Waterveyor Abrasive
Removal System
End effector
The Mach 3b and Mach 4b Series systems are available
with several end effector options:
Dynamic Waterjet XD end effector (DWJ-XD)
Dynamic Waterjet end effector (DWJ)
Non-DWJ end effector
Abrasivejet system
The abrasivejet system uses an abrasive delivery hopper
and a cutting head.
The abrasive delivery hopper is available as an integrated
hopper with no external controls, or a standalone unit
with external controls.
The abrasive level switch on an integrated hopper is
monitored through the software.
Refer to the PASER manual that shipped with your
system.
Catcher tank
The catcher tank supports the cutting envelope surface.
The levelness of the tank and the water in the tank is
important to maintain consistent cutting quality.
Light curtain safety device

Mach 3b and Mach 4b Series systems with a Dynamic
Waterjet XD end effector are equipped with a light curtain to maintain a safety perimeter around the machine.
Spray containment kit

Mach 3b and Mach 4b Series systems with a Dynamic
Waterjet XD end effector are equipped with a
multi-panel spray containment system to minimize spray
outside of the cutting area.
8 | M-406
CHAPTER 1
System Specifications
Machine features
Options
PC-based control
Vacuum assist
FlowMaster PC controller includes CAD, path ordering,

machine controls and diagnostics, plus optional part
nesting.
Helps when piercing brittle materials such as glass, composite, or stone.
Abrasive flow monitor

Digital servo system
X and Y axes (digital AC servos) provide high accuracy
and low maintenance.
Alarm activates when abrasive flow rate exceeds high or

low limits.
X,Y,Z jog pendant

Ball screw drives
The Mach 3b and Mach 4b Series System uses high-precision ball screws and ways.
Allows the operator to adjust cutting head position remotely from the main control console.
M-406 | 9

Installation requirements
Environment
Oil requirements
The pumps used with the Mach 3b and Mach 4b Series

System are designed only for factory or shop use.
Use of recommended oils is vital to proper operation

and maintenance of the system.
Ambient temperature 60 to 100F (15.5 to 38C)
Intensifier pump
Relative humidity
Up to 90% @ 100F (38C)

non-condensing
Airborne dust/
contaminants
Minimal
Radio frequency
interference
Minimal
Lighting
Adequate to operate & service

the equipment
Use an oil that does not contain anti-wear additives; the

following oils are recommended, but other manufacturer's equivalents can be used:
Mobil DTE Medium, Shell Turbo T 46,Chevron Tur-
bine Oil GST 46, Exxon Teresstic 46, or Texaco Regal

R&O 46
Kinematic viscosity 50i-S/100i-D:
310 SSU @ 100F (38C)
HyperJet 94i-S/94i-D:
240 SSU @ 100F (38C)
System capacity
50i-S: 32 gallons (121 L)

100i-D: 34 gallons (129 L)
HyperJet 94i-S: 25 gallons (95 L)
HyperJet 94i-D:37 gallons (140 L)
Filtration
2 microns, continuous flow
Cooling
Oil-to-water heat exchanger
Optimum oil tem- 105F (40.5C)

perature
HyPlex Hybrid pump

Use an oil that does not contain anti-wear additives.
Shell Rotella (or equivalent) is recommended, but other
manufacturer's equivalents can be used.
Use SAE 30 unless ambient temperature is above 90F
(32C), then use SAE 40.
10 | M-406
Reservoir
capacity
2.5 qt (2.4 liter)

Fill reservoir until oil is visible on the
dipstick.
SAE designation
MS, SC, or SD
CHAPTER 1
Water requirements
The 50i-S and 100i-D intensifier pumps require two
sources of water: cutting and cooling. Also required

are three water drain lines for coolant, leakage, and
bleed-down water. Leakage and bleed-down water
drain lines may be plumbed together when necessary.
The leakage drain must be separate where local regulations do not permit oil in drains. Specific requirements are defined below.
The HyperJet 94i-S and HyperJet 94i-D intensifier
pumps each require one water source. Also required

are three water drain lines: coolant drain, leakage
drain, and bleed-down water. Leakage and
bleed-down water drain lines can be plumbed together when necessary. The leakage drain must be
separate where local regulations do not permit oil in
drains. Specific requirements are defined below.
The HyPlex Hybrid pump requires a single source of
water, and one drain line.
Cutting water
Cooling water (to heat exchanger)

For intensifier pump only
Dual heat exchangers regulate heat build-up in the hydraulic oil. Optimum hydraulic oil temperature is 105F
(40.5C). Tap water is routed first to a heat exchanger in
the pump case drain line, then to a heat exchanger in
the intensifier return line.
A thermostatically-controlled cooling water flow control
valve designed for partially open operation is installed in
the line to regulate the water flow for maximum water
conservation.
Water flow must be sufficient to ensure that the hydraulic oil reservoir temperature is always maintained below
110F (43C). Cooling water flow rate is typically 3 gpm
(11 lpm) per 50 hp at an inlet water temperature of
60F (15C).
Waterjet systems perform better with soft water. Water
with low levels of minerals and acid will maximize heat
transfer efficiency and heat exchanger life.
CAUTION
A high concentration of dissolved solids in the inlet water
(especially silicates and calcium) can reduce waterjet nozzle
life. If water quality is poor and filtration will not correct it, the
customer must add additional water treatment equipment.
Contact Flow Technical Service for more information.
Flow recommends the use of a water softener to

pre-treat the cutting water.
Water pressure
Water pressure to the intensifier pump must stay be-
tween 20 and 100 psi (1.4 and 6.9 bar) at all times.
Water pressure to the HyPlex pump must stay be-
tween 40 and 60 psi (2.8 and 4.1 bar) at all times.
Water flow rate

Systems should be sized for 150% of your pump capacity, and should match your intended maximum duty
cycle.
M-406 | 11

Water interface connections

Flow recommends the installation of manual on/off
valves in the high-pressure, inlet water, and cooling water lines. Locate valves as close as possible to the pump
interface connection to make them easier to service.
Coolant water lines must be non-corrosive pipe or rubber hose. Rubber hose (per SAE Standard 20R1, 30R1,
or equivalent) is recommended.
Cutting water lines (from the filtering system to the intensifier pump) must be as short as possible and must be
PVC, copper, or equivalent. Do not use galvanized iron
pipingit will introduce minerals to the water, which
will shorten orifice life.
Intensifier pump utility connections

Connect inlet water line to FILTERED WATER IN.
Connect LEAKAGE WATER to the appropriate
drain or bucket (can contain oil).

Connect BLEED-DOWN WATER to the appropriate
drain.
Connect cooling water supply line to COOLING
WATER IN.
Connect COOLING WATER OUT to the factory
drain system.
Note: Purge the inlet water lines of debris
before completing the connection to the pump.
HyPlex Hybrid pump utility connections

Connect inlet water line to inlet water solenoid valve.
Connect ECV or PCV to the appropriate drain.
CAUTION
To ensure that the Pac-V does not entrain catcher tank drain water and damage the Pac-V, connect the Pac-V drain line directly
to an outlet drain, suspend the line above the catcher tank, or
install a check valve in the Pac-V drain line.
Connect inlet air to pneumatic air regulator.
12 | M-406
CHAPTER 1
Drain requirements
High-pressure tubing
Intensifier pump
Cooling water drain
Cooling water leaving the intensifier pump is considered

waste water. This water can be routed to a waste water
recovery system, a recirculation system, or a drain
whichever is most applicable for the installation. If the
water is reused for cooling, a commercial water cooling
system can be used.
If the cooling water outlet is routed directly to a waste
water drain, you must have a minimum drain capacity of
5 gpm (19 lpm).
Bleed-down water
The bleed-down valve exhausts water through the

BLEED DOWN WATER port on the bulkhead. This can
be connected to the same drain as the catcher overflow,
if required.
Intensifier and HyPlex pumps

Leakage drain (oil or water)
The pump has a drip pan to collect oil or water leakage

from the seals. Leakage is usually negligible; however,
the drain line is sized to accommodate the worst case (if
the bleed-down valve opens) of 10 gpm (38 lpm).
High-pressure tubing certified for continuous operation

at 60,000 psi (4138 bar) is used to route high-pressure
water from the intensifier to the attenuator, and from the
attenuator to the rear bulkhead fitting. The same type of
tubing also connects the intensifier pump to the cutting
equipment.
HyperJet 94i-S or HyperJet 94i-D intensifer pump

at 94,000 psi (6483 bar) is used to route high-pressure
water from the intensifier to the attenuator, and from the
attenuator to the rear bulkhead fitting. The same type of
tubing also connects the intensifier pump to the cutting
equipment.
HyPlex Hybrid pump

at 55,000 (3792 bar) is used to route high-pressure water from the HyPlex pump to the cutting equipment.
Note: Refer to manual M-127, Small High-pressure Components or M-393, Hyperpressure Small High-pressure
Components for more information on high-pressure tubing, components, and related service.
Do not connect the leakage water drain to the coolant

water drain line or any other pressurized drain system.
Catcher tank
Overflow from the catcher tank can be routed to an
optional 3-tier waste water recovery system, a
recirculation system, or a drain.
Water from the catcher tank overflow outlet can contain
variable amounts of abrasive particulate.
M-406 | 13

Startup procedures
Starting the HyperJet 94i-S or HyperJet 94i-D
intensifier pump after installation
e. Reconnect the intensifier fittings and supply

hoses.
Use this procedure after the equipment is first installed,

and after an intensifier has been disassembled for
service.
CAUTION
Before starting the equipment:

Be sure you know how to stop it.
Read the manuals, get training from an experienced
operator, and review the safety precautions.

Follow a written check list that includes an inspection
for needed or ongoing service, damaged or missing

parts, leaks, or anything that could make the equipment unsafe to operate.
Make sure doors and covers are in place.
Call out "START-UP!"
Stand in a place that is protected by safety devices
and within reach of an emergency stop switch.
Any debris left in the water supply lines can enter the
intensifier and damage the high-pressure components.
Such damage IS NOT covered by your warranty.
Pumps are shipped without hydraulic oil. You must add oil
to the reservoir and the hydraulic pump case before operating
the pump or you will SEVERELY damage the system.
5. Close the hydraulic oil reservoir drain valve and fill

the reservoir until oil is visible in the sight gauge. Use
an oil that does not contain anti-wear additives. The
reservoir holds about 27 gal (102 L).
6. Loosen the hydraulic pump suction line flange fittings
and crack open the flange until oil leaks out. This ensures that all air is bled from the suction line. Tighten
the flange fittings.
WARNING
7. Remove all tools, rags, parts, and debris from around

the pump.
Do not operate the pump with uncertified parts.

Explosive separation of the parts and serious
bodily injury could occur. Contact Flow or seek
professional installation assistance.
8. Open the external cutting and cooling inlet water

valves to the intensifier pump. Check all connections
for leaks.
All operators and service personnel must review the safety

precautions in Chapter 2 of this manual and in all manuals
provided with this equipment before starting the equipment.
Cutting equipment and nozzles must be installed and
working before operating the pump. Operating
the pump without proper line restriction will
damage high-pressure components.
Starting the pump

1. Fill the hydraulic pump with hydraulic oil via the upper case port before starting the unit.
2. Make sure the inlet water filters are correctly
installed.
3 Locate the water supply hoses on the intensifier. Remove tie-wraps and plastic caps.
4. Purge the inlet and cooling water systems of air and
debris:
a. Bypass the solenoid valve, if applicable.
b. Insert a fitting into each quick-disconnect coupling and connect to a temporary drain line (use
the fitting threaded into the intensifier end cap).
c. Open the external inlet and cooling water valves.
d. Purge the inlet and cooling water lines for three
minutes, then close the external water valves or
push the E-stop in.
14 | M-406
9. Open the high-pressure water valve downstream of

the intensifier pump and click Low Pressure on the
Run Machine screen.
10. Locate the hydraulic pump and motor coupling.
Open the cover so you can see the coupling and
watch motor rotation.
11. Click on the pump ON/OFF button to start the
pump. Wait for the 5 second booster pump delay,
then click the button a second time to stop the pump
as soon as the main electric motor starts. Make sure
the motor shaft rotates in the same direction as the
arrow on the hydraulic pump.
If the shaft rotates in the opposite direction, first reverse the electric power phase to any two motor
leads to change motor shaft rotation, and then loosen
the hydraulic pump suction line flange fittings and
crack open the flange until oil leaks out. This ensures
all air is bled from the suction line. Retighten the
flange fittings. When rotation is correct, replace the
cover.
Note: If using a motor starter, contact the motor

starter supplier or FLOW for more information.
CHAPTER 1
HyperJet 94i-S intensifier pump
HyperJet 94i-D intensifier pump
M-406 | 15

12. Purge trapped air from the hydraulic system before continuously operating the pump. Jog the
pump by successively clicking the pump ON/OFF
button. Wait for the 5 second booster pump delay
in between clicks. Wait a few moments after each
jog until an audible change indicates that the
pump is filled with oil. If the hydraulic pump fails
to pick up pressure after 4 or 5 jogs, make sure
the oil reservoir is full.
CAUTION
Operating the pump without oil
can damage the hydraulic pump.
Pressure conversion table

87,000 psi (6000 bar) intensifier
Hydraulic pressure
Water pressure
PSI
Bar
PSI
Bar
500
1000
1500
2000
2500
2750
34
69
103
138
172
190
15,700
31,400
47,100
62,800
78,500
87,000
1082
2165
3247
4330
5412
6000
13. Click the pump ON/OFF button to start the pump.

The hydraulic pump should idle at low pressure.
WARNING
Do not tighten any loose or leaking connections while
the pump is operating or the line is pressurized.
14. Run the pump at low pressure for 1015 minutes.

Check for leaks.
15. Increase the high-pressure water pressure by clicking on HIGH PRESSURE. Check continuously for
leaks or other problems.
16. Operate the pump an additional 510 minutes
while checking for leaks.
17. While the hydraulic system is warming up, measure the oil temperature in the reservoir using a
surfacecontact thermocouple or a thermometer.
Optimum oil temperature is 105110F
(4043C); adjust the cooling water flow control
valve on the bulkhead if necessary.
18. Click ON the pump ON/OFF button to stop the
pump.
19. Check the oil level in the sight gauge and add oil
as needed.
20. Close all water valves.
21. Thoroughly inspect the complete installation for
any incomplete or low-quality work. Do not sign
off the installation until all problems have been resolved and all quality-control inspections have
been completed.
Note: All personnel must carefully read this manual
before operating or servicing the pump. Flow Technical Service assistance is required when installing the
system equipment. Refer to manual MS-2266, Customer Support and the preinstallation manual.
CAUTION
All operators and service personnel must
review the safety precautions in Chapter 2
before starting this equipment.
16
CHAPTER 1
Starting the 50i-S or 100i-D

intensifier pump after installation
and after an intensifier has been disassembled for
service.


e. Reconnect the intensifier fittings and supply

hoses.
CAUTION
Any debris left in the water supply lines can enter the
intensifier and damage the high-pressure components.
Such damage IS NOT covered by your warranty.
Pumps are shipped without hydraulic oil. You must add oil
to the reservoir and the hydraulic pump case before operating
the pump or you will SEVERELY damage the system.
5. Close the hydraulic oil reservoir drain valve and fill

the reservoir until oil is visible in the sight gauge. Use
an oil that does not contain anti-wear additives (recommended oils are listed earlier in this chapter). The
reservoir holds about 27 gal (102 L).
6. Loosen the hydraulic pump suction line flange fittings
and crack open the flange until oil leaks out. This ensures that all air is bled from the suction line. Tighten
the flange fittings.
WARNING
7. Remove all tools, rags, parts, and debris from around

the pump.

8. Open the external cutting and cooling inlet water

valves to the intensifier pump. Check all connections
for leaks.

Start-up steps
1. Fill the hydraulic pump case with oil via the upper
case port before starting the unit.
2. Make sure the inlet water filters are correctly
installed.
3 Locate the water supply hoses on the intensifier. Remove tie-wraps and plastic caps.
4. Purge the inlet and cooling water systems of air and
debris:
a. Bypass the solenoid valve, if applicable.
b. Insert a fitting into each quick-disconnect coupling and connect to a temporary drain line (use
the fitting threaded into the intensifier end cap).
c. Open the external inlet and cooling water valves.
d. Purge the inlet and cooling water lines for three
minutes, then close the external water valves or
push the E-stop in.
9. Open the high-pressure water valve downstream of

the intensifier pump and click Low Pressure on the
Run Machine screen.
10. Locate the hydraulic pump and motor coupling.
Open the cover so you can see the coupling and
watch motor rotation.
11. Click on the pump ON/OFF button to start the
pump. Wait for the 5 second booster pump delay,
then click the button a second time to stop the pump
as soon as the main electric motor starts. Make sure
the motor shaft rotates in the same direction as the
arrow on the hydraulic pump.
If the shaft rotates in the opposite direction, first reverse the electric power phase to any two motor
leads to change motor shaft rotation, and then loosen
the hydraulic pump suction line flange fittings and
crack open the flange until oil leaks out. This ensures
all air is bled from the suction line. Retighten the
flange fittings. When rotation is correct, replace the
cover.
Note: If using a motor starter, contact the motor
starter supplier or FLOW for more information.
M-406 | 17

50i-S intensifier pump
100i-D intensifier pump
18 | M-406
CHAPTER 1
12. Purge trapped air from the hydraulic system before

continuously operating the pump. Jog the pump by
successively clicking the pump ON/OFF button. Wait
for the 5 second booster pump delay in between
clicks. Wait a few moments after each jog until an audible change indicates that the pump is filled with oil.
If the hydraulic pump fails to pick up pressure after 4
or 5 jogs, make sure the oil reservoir is full.
CAUTION
Operating the pump without oil
can damage the hydraulic pump.
13. Click the pump ON/OFF button to start the pump.

The hydraulic pump should idle at low pressure.
Pressure conversion table

60,000 psi (4138 bar) intensifier
Hydraulic pressure
Water pressure
PSI
Bar
PSI
Bar
500
1000
1500
2000
2500
2750
3000
34
69
103
138
172
190
207
10,000
20,000
30,000
40,000
50,000
55,000
60,000
690
1379
2069
2759
3448
3793
4138
WARNING
Do not tighten any loose or leaking connections while
the pump is operating or the line is pressurized.
14. Run the pump at low pressure for 1015 minutes.

Check for leaks.
15. Increase the high-pressure water pressure by clicking
on HIGH PRESSURE. Check continuously for leaks or
other problems.
16. Operate the pump an additional 510 minutes while
checking for leaks.
17. While the hydraulic system is warming up, measure
the oil temperature in the reservoir using a surfacecontact thermocouple or a thermometer. Optimum
oil temperature is 105110F (4043C); adjust the
cooling water flow control valve on the bulkhead if
necessary.
18. Click ON the pump ON/OFF button to stop the
pump.
19. Check the oil level in the sight gauge and add oil as
needed.
20. Close all water valves.
21. Thoroughly inspect the complete installation for any
incomplete or low-quality work. Do not sign off the
installation until all problems have been resolved and
all quality-control inspections have been completed.
Note: All personnel must carefully read this manual before operating or servicing the pump. Flow Technical
Service assistance is required when installing the system
equipment. Refer to manual MS-2266, Customer Support and the preinstallation manual.
CAUTION
All operators and service personnel must
review the safety precautions in Chapter 2
before starting this equipment.
M-406 | 19

Starting the HyPlex Hybrid pump

after installation
and after the pump has been disassembled for service.



WARNING
HyPlex Hybrid pump

Starting the system

1. Flush debris from all water supply hoses before connecting them to the pump.
CAUTION
Debris in the water supply line can cause extensive
damage to the high-pressure components. Such
damage IS NOT covered by warranty.
2. Fill the pump case with one of the recommended

oils. The pump capacity is 2.5 qt (2.4 L). Fill the reservoir until the oil is visible on the dipstick.
CAUTION
Never operate the pump without oilthis can cause
extensive damage and is not covered by warranty.
3. Make sure water lines, air lines, and drain lines are
correctly connected and routed.
20 | M-406
CHAPTER 1
4. Clear all tools, parts, and rags from around the pump.
Check all areas in and around the pump for foreign
objects and debris.
CAUTION
The inlet water valve must be open before operating
the pump. Operating the pump with the inlet
water valve closed will cause damage.
5. Open the inlet water valve; check all connections for

leaks.
CAUTION
operational before operating the pump. Operating the
pump without proper line restriction can cause damage.
6. Place the main electrical disconnect in the ON

position.
7. Release the E-stop button.
8. Activate the FlowCUT program and open a part program. Select Run Machine. The screen will display
the pump on/off control. Verify that the low pressure
icon is checked. Turn the pump on by clicking on the
pump ON/OFF button.
CAUTION
Do not try to tighten any loose or leaking connections while
the pump is operating or while the line is pressurized.
9. If one of the maintenance kits has just been installed,

click on Setup | Service record in the menu bar on
the Run machine screen. You must enter pump hours
and kit installation information or the pump will not
run.
10. Run the Temperature Input Offset Adjustment
routine.
11. The scaling factor (0.13 for 30 & 50 hp pumps) needs
to be adjusted if pump pressure calibration is required. See Calibrating the pump control system in
manual M-397.
12. Open the manual relief valve on filters.
13. Turn the pump on by clicking on the pump ON/OFF
button. When the pump reaches 55,000 psi
(3792 bar), operate the pump at this pressure for
5-10 minutes while checking for leaks. Correct as
required.
14. Click on the low-pressure icon. Check all connections
for leaks.
15. Click on the high-pressure icon.
16. Turn the pump off, exit FlowCUT, and press the
E-stop button.
M-406 | 21

System operation
The ultrahigh-pressure pump is operated from the
FlowMaster PC controller. See the FlowCUT User's
Guide for more detailed information on running the machine. A pump operation button on the FlowCUT RUN
MACHINE screen is used for starting and stopping the
pump. Select HIGH PRESSURE or LOW PRESSURE for
the dual-pressure feature.
Fault indicators
Machine shutdown
The machine should be shut down if it will not be run
for an extended period of time (e.g., overnight). To shut
down the machine normally, follow these steps:
1. Jog the machine manually so that the X and Y axes
are near the HOME position (X0, Y0). This is not a
necessary step, but it will make it more convenient to
HOME the machine next time you start up the machine.
Manually jog the Z-axis to its highest position off of
the cutting surface.
The safety light that is integrated into the buttons of the

PC monitor enclosure alerts the operator of machine
faults. The light will flash during a Warning condition,
and remain steady for a Shutdown condition. The operator can determine the specific fault condition by viewing messages on the FlowCUT screen.
2. Exit FlowCUT and shut down Windows.
Machine startup
5. Turn off the power:
To start the machine from a cold start (no power), make

sure that main air and main water supplies are turned
on to the machine, then follow these steps:
1. Turn on main power disconnect located on the far
right side of the electrical enclosure. If there is an additional disconnect on the wall that feeds power to
the machine, make sure this is turned on as well.
3. Push the CONTROL ON button on the right side of

the display monitor enclosure.
4. Engage the E-stop button on the right side of the display monitor enclosure.
If you need to leave the Main Power Disconnect

switch on in order to continue to supply power
to peripheral equipment (such as the Abrasive
Recycler), turn off power to the PC using the
switch on the front of the PC.
Otherwise, turn off power to the machine using
the Main Power Disconnect switch.
2. Turn on power to the machine PC.

3. Let the PC boot up to the basic Windows start
screen, where the FlowMaster icons are located.
4. Disengage all E-Stop switches.
5. Push the E-Stop reset button. The button will light up.
6. Push the CONTROL ON (OT Bypass) button. The
button will light up.
7. Start FlowCUT by double-clicking the FlowCUT icon.
8. At this point, you can load a part file (ORD file) and
set the proper Jet Setup and material/thickness properties, but this is not necessary.
9. Click on the Run Machine icon. The screen should
change to show the machine controls (Water, Abrasive, Pump, and so on).
10. Home the Z-axis. Click on the Home Z,A,B-axis icon.
11. Home the X,Y-axes. Click on the Home X,Y-axes
icon, then choose Go to Machine Home from the
selection list. The machine should then move to the
front left corner of the work envelope and is ready to
run at that point.
22 | M-406
CHAPTER 1
Running the pump

HyperJet 50 or HyperJet 100 intensifier pump
When the machine is in position to start a cut, click on
the ON pump button. The intensifier pump will not start
immediately; the water booster pump turns on first to
charge the system. After approximately 5 seconds, the
intensifier pump will start and ramp up pressure. The
pump uses an electronic proportional control valve to
automatically ramp up high-pressure water. The digital
high-pressure gauge on the FlowCUT screen indicates
the level of water pressure in the system. When the system reaches the desired operating pressure, you can begin cutting.
Click the OFF pump button to turn off the pump. All
system pressure is bled to 0 psi within one second of
shutting down the pump.

the ON pump button. The intensifier pump will not start
immediately; first the booster pump turns on to charge
the system. After approximately 5 seconds, the pump
starts and begins ramping up to pressure. The pump uses
an electronic proportional control valve to automatically
ramp up hydraulic pressure. The digital highpressure gauge on the FlowCUT screen indicates the
amount of water pressure in the system. When the system reaches the desired operating pressure (60,000 psi/
4138 bar) you can begin cutting.
Click on the OFF pump button to turn off the pump. All
HyPlex pump
the ON pump button. The HyPlex pump will not start
immediately; first the WATER ON solenoid energizes. After approximately 5 seconds, the HyPlex pump starts
and begins ramping up pressure. The pump uses an
electronic proportional control valve to automatically
ramp up high-pressure water. The digital high-pressure
gauge on the FlowCUT screen indicates the amount of
water pressure in the system. When the system reaches
the desired operating pressure (55,000 psi/3792 bar) you
can begin cutting.
Click on the OFF pump button to turn off the pump. All
Using dual pressure

Brittle materials, such as glass, stone, or composites,
should be pierced at a lower operating pressure (such as
20,000 psi/1379 bar). To select high or low pressure,
highlight either the HIGH PRESSURE or LOW PRESSURE
box to the right of the PUMP on/off button.
The default setting is HIGH PRESSURE, which is nor-
mally set for an operating pressure of 60,000 psi

(4138 bar) for an intensifier pump, and 87,000 psi
(6000 bar) for a HyperJet pump.
Selecting LOW PRESSURE will lower the pressure,
normally 12,00020,000 psi (8281379 bar).

Use the LOW PRESSURE setting in conjunction with the
FlowMaster PIERCE ALL HOLES FIRST function to pierce
holes in a given program at low pressure before cutting.
Changing low-pressure or high-pressure

setting (intensifier pump)
Use the Jet Setup screen to enter a different low- or
high-pressure setting.
Warning and shutdown sensors

The ultrahigh-pressure pump is equipped with several
shutdown and warning sensors.

Refer to manual M-349, 50i-S Pump or M-351, 100i-D
Pump.
Shutdown sensors for low hydraulic oil level, high hy-
draulic oil temperature, and low inlet water pressure.

Warning sensors for high pump bleed-down tempera-
ture, high check valve temperature, low inlet water

pressure, and high hydraulic oil temperature.
HyPlex Hybrid pump

Refer to manual M-354, HyPlex Hybrid Pump.
Shutdown sensors for low inlet water pressure and
high-pressure cylinder over-temperature.

Warning sensors for high-pressure cylinder over-tem-
perature and inlet water temperature.
Calibrating the pump to a gauge

Parameters for setting the low- and high-pressure
setpoints are located in one of the initialization files
(acscard.ini) in the FlowMaster software. Refer to the
manuals that came with the software for information on
using the Jet Setup screen.
M-406 | 23

Control panel
Control On (OT Bypass)
This illuminated pushbutton turns on control power to
the machine. Power is switched on to the servo motor
amplifiers as well as the 24 VDC I/O controls. The
switch also serves as a machine overtravel bypass. If the
X or Y axis of the machine is jogged or run into the
overtravel limits, this switch must be held in while the
machine of jogged off the limit switch. The E-stop switch
must be disengaged and the E-stop reset switch must be
pushed before control power can be turned on. The
pushbutton is illuminated when control power is on.
Z-axis raise/lower
Controls the position of the z-axis manually. Moves the
cutting head assembly up or down depending on position of the switch.
E-stop reset
Resets an E-Stop. This illuminated pushbutton is lit when
the machine is NOT in an E-stop state. This switch must
be used to reset the machine control after an E-stop
condition.
Emergency stop (E-Stop)

Stops the machine in an emergency situation. All control
power is killed, motion is stopped, and the UHP pump
is turned off. If the machine is ready to be shut down for
maintenance or as part of the daily routine, this button
can be used to turn control power off before shutting
down the PC.
24 | M-406
CHAPTER 2
Safety
The comprehensive list of safety precautions in this
chapter (and in the rest of the manual) must be followed
to ensure safe operation of the equipment. The equipment must only be used, serviced, and repaired by persons who are familiar with the operating instructions and
the service procedures provided in this and other FLOW
manuals.
These precautions must be read and understood by
everyone operating and maintaining the equipment
before they start working with the equipment.
In addition to adhering to the safety rules in this manual,
all applicable local safety agency rules (including OSHA,
state, and national) must be adhered to.
Applicable plant general safety precautions must also be
followed.
The user shall practice and promote safety

at all times to avoid potential injuries and
unnecessary production shutdowns.
Safety precautions
FLOW designed your high-pressure waterjet cutting system and related equipment with safety in mind.
Throughout the manual, safety precautions and warnings
for specific operations are highlighted. Safety precautions
are also posted on the equipment. The operator and service personnel shall pay particular attention to these precautions at all times.
The label shown is

available in two sizes:
Part # 006317-1
3.75 x 6 in.
(95 x 152 mm)
Part #009837-1
1.8 x 3 in.
(46 x 76 mm)
Warnings, cautions, and notes

Service procedures in the waterjet manuals include
safety warnings, cautions, and notes that must be read,
understood, and adhered to. These are specific categories of safety notices, and are defined as follows:
WARNING
Highlights an operating condition or
service procedure that can result in
death or serious injury.
CAUTION
Highlights an operating condition or service
procedure that can lead to impaired system
operation or equipment damage.
Note: Highlights an operating or service procedure or

condition that is considered essential for efficient operation and service.
Operators of a high-pressure waterjet cutting system

must treat the system as they would treat any highspeed cutting tool. Although the waterjet may appear
harmless, it is a high-energy cutting tool capable of cutting many nonmetallic materials such as composites,
plastics, and wood products. Misuse of this equipment
or carelessness in its application can be extremely hazardous to operating personnel. Always treat the waterjet
cutting system with respect.
M-406 | 25

Safety tips
Do not let the waterjet stream touch any part of your
body.
Do not point the waterjet at anyone.
Take the system out of service during maintenance.
The controls shall be locked and marked with a warning sign.

All personnel working on or around the equipment
shall pay particular attention to all warning signs and

notices posted in the plant and on the equipment.
Protective guards, shields, and covers must be in
place on the equipment at all times.

First aid facilities shall be provided in convenient lo-
cations throughout the plant. These locations must be

known by all personnel.
The work area around the equipment shall be clean
and free of debris. Oil spillage results in slippery

floors and must be removed immediately.
Any conditions that could result in injury must be re-
ported to the plant supervisor without delay.

Safety shoes, glasses, and hearing protection must be
worn by all personnel working around the equipment. Do not wear dangling jewelry (such as rings,
watches, or necklaces) when working around any
equipment that has moving parts.
Mechanical system
Don't start the system unless you know how to stop it.
Never maintain, service, or clean around the equip-
ment while it is operating.

Using the wrong tools can result in injury or costly
damage to the equipment.

Never climb on or around the equipment on make-
shift devices. Use only approved catwalks, ladders, or

platforms.
Do not exceed specified pressure settings for pneu-
matic or hydraulic components. Exceeding these

limits can cause serious injury to personnel or equipment damage.
Shield and bundle equipment hoses and cables so
Electrical system
Only properly trained personnel shall perform electri-
cal or electronic troubleshooting and servicing.

Always assume that power is ON in all electrical sys-
tems. Always check and lock out the main power

switches before servicing the equipment. Post a sign,
"Maintenance in ProgressDo Not Energize.
Live electrical circuits are present in the control con-
sole whenever the master disconnect is on, regardless

of whether the EMERGENCY STOP is engaged.
Disconnect circuit breakers and lock them in the OFF
position before servicing the electrical system. If this

isn't possible, have someone stand by to prevent anyone from powering up the system.
Be especially careful when servicing the power sys-
tem in a damp environment.

Never alter or bypass protective interlocks or devices
unless specifically instructed to do so, and only if all

precautions are followed.
Give capacitors enough time to discharge. If this isn't
possible, carefully discharge them manually.

Do not use jumper wires across fuses or fuse holders.
Make sure all tools are well insulated.
Use only proper test apparatus; check it regularly to
make sure it works properly.

Use caution when connecting a test probe to test
points.
All replacement wires shall conform to the manufac-
turer's specifications, including color coding, wire

numbers, and size.
Close the control panel doors or junction box covers
after servicing.
Waterjet cutting system

High-pressure water can remain in the system for an
extended time after shutting down the high-pressure

water source. System pressure can be relieved by
opening any valve downstream of the outlet valve.
Always bleed down the system pressure before
servicing any part of the system.
they do not obstruct the operator's freedom of

movement.
Do not touch weep holes with your bare hands or try
Be alert at all times when working around the
The waterjet stream is a knife. Do not put anything in
equipment.
Clear all tools, parts, and rags from any moving parts
after servicing the equipment.
to stop water by plugging the holes.

its path that you do not intend to cut.
Wear a face shield whenever required by the operat-
ing instructions.
Do not remove protective shields from high-pressure
tubing. If shields are removed for servicing, they must

be replaced before starting the system.
26 | M-406
CHAPTER 2
Safety
Torque all fittings to the manufacturer's specifications.
Eye protection
At a minimum, operators must
Stepping or leaning on high-pressure water tubing
wear safety glasses with side

shields and a visor, or goggles and
a visor, to guard against spray and
flying debris.
can break connections and cause leaks.

High-pressure fittings, valves, and tubing must be cer-
tified for 60,000 psi (4138 bar) for 60K systems and
87,000 psi (6000 bar) for Hyperjet systems. Do not
substitute when making alterations or additions to the
high- pressure water system.
All eye protection shall meet ap-
propriate ANSI requirements for

that type of eye protection.
Do not alter or eliminate stress relief tubing coils.
Some states and countries have
Follow the tubing manufacturer's recommendations
their own eye protection rules that

must be followed.
for high-pressure tube bending radii.

Do not exceed specified operating pressures for
high-pressure components.
Head protection
Do not over-torque fittings or over- bend swivels.
Helmets must be worn at all times
by all personnel within the work

area. Helmet material must withstand mechanical shock to 10 G in
8 ms without fracturing.
Follow the manufacturer's recommendations for ser-
vicing the equipment, and use only original manufacturer replacement parts.
Follow the manufacturer's system startup procedure
to ensure safe operation.

Use care when lifting equipment covers during
Hand protection
Operator must wear gloves at all
operation.
times. Leather gloves are

preferred.
High-pressure waterjet cleaning tools

Turn off equipment and relieve water pressure before
replacing nozzles, tips, or bits.

Hang a sign on the power supply control panel warn-
Hearing protection
Operators and other personnel ex-
ing that the equipment is being serviced and is not

available for use until servicing is complete.
posed to noise levels of more than

90 dBa for more than 1 hour must
wear suitable ear protection. Ear
plugs and muffs are usually adequate.
Replace all protective covers and shielding on equip-
ment before operation.

Check for leakage after nozzle or tip replacement
and correct immediately.

Use only FLOW manufactured or approved waterjet
Foot protection
nozzles, cleaning tips, and drilling or cutting bits.
Operators and other personnel
must wear safety footwear with

steel toe-caps a minimum of
0.02-in. (5 mm) thick. The toe cap
must cover at least 30% of the
footwear length.
Protective clothing
Workers operating hand-held, high-pressure waterjet cutting or cleaning equipment and those working nearby
should wear protective clothing and safety devices as described in this section. FLOW recommends that worksite safety personnel approve all safety equipment and
clothing for everyone working around waterjet cutting
equipment.
The operators footwear must be
equipped with metatarsal guards

to provide instep protection.
Body protection
Waterproof garments only protect the operator from
spray and flying debris. They do NOT deflect direct

jet impact.
M-406 | 27

Emergency medical information

WARNING
NEVER point a waterjet cutting or cleaning tool at
yourself or at any person. Do not aim a waterjet tool
at anything you do not intend to cut.
Anyone who incurs equipment-related injuries while operating high-pressure water equipment should be given
immediate hospital attention. It is vital that medical personnel have information about this type of injury. Therefore, all waterjet operating personnel should carry a
waterproof emergency medical tag or card that describes
their work and the nature of injuries inherent in using
waterjet cutting devices. The tag or card should contain
the information in the sample below.
The card illustrated below can be purchased from FLOW
(P/N A-8466). It is also available in French, German, Italian, and Spanish. Simply order part number A-8466F, G,
I, P, or S.
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.
FLOW INTERNATIONAL CORPORATION

23500 64th Avenue South
Kent, Washington 98032 USA
(253) 850-3500
This person has been working with water jetting at pressures to

92,000 psi (634 MPa, 6345 bar) with a jet velocity of 3900 fps
(1190 mps). This should be taken into account during diagnosis.
Unusual infections with microaerophilic organisms occurring at
lower temperatures have been reported. These may be
gram-negative pathogens, such as those found in sewage. Bacterial swabs and blood cultures may therefore be helpful. A local poison control center should be contacted for additional
treatment information.
28 | M-406
CHAPTER 3
60K End Effectors

Two 60K end effectors are available for the Mach 3b
and Mach 4b Series System: Standard and Dynamic.
Both end effectors use the PASER ECL Plus cutting head.
Standard end effector

The standard end effector uses a cutting head that is
mounted perpendicular to the cutting envelope.
The standard end effector has four main components:
Z-axis
High-precision cutting head
On/off valve
Height sensor
Dynamic Waterjet end effector

The Dynamic Waterjet (DWJ) is a wrist tilting end
effector designed for flat-stock machines. Its revolutionary design provides a better way to correct two common
drawbacks to abrasivejet cuttingtaper and inside corner kickback.
Tilting the head removes the taper from one side of the
cut, leaving a vertical cut on the side of the part. Tilting
the jet tip into the direction of travel reduces drag, so
cutting speeds on inside corners can often be increased
without damaging the underside of the part.
The DWJ end effector has five main components:
Z-axis
Mini-wrist
Mini on/off valve
Height sensor
These are illustrated and described in this chapter.

Tips and guidance on using the DWJ effectively can be
found in manual MS-2276, How To Be Successful With
Dynamic Waterjet.
M-406 | 29

Z-axis
Work envelope
Maintenance
Tilting a cutting head influences the overall travel of an

X,Y system. A tilting head with the DWJ kinematics uses
X,Y,Z-axes travel to compensate for variation in the tool
center point. Depending on tool length, the maximum
travel of the X- and Y-axes is decreased by about
4 in. (50 mm).
The components used in the Z-axis are protected
The available travel of the Z-axis is influenced by tilting

the cutting head and by mixing tube length. It is important when using the DWJ to consider what mixing tube
will be used. With DWJ on the system, the minimum
tool length must be able to reach the catcher tank grid
when the head is tilted to the maximum A- and B-axis
angles.
In case of a collision with any foreign object, please
from everyday machine operation, and should provide years of reliable operation without servicing.
There are no serviceable parts inside the Z-axis and
the unit must never be opened except by Flow
technicians.
consult Flow Technical Service for information on
realignment.
The FlowMaster screen automatically shows the available

cutting envelope.
30 | M-406
CHAPTER 3
60K End Effectors
DWJ wrist assembly

The DWJ wrist assembly is powered by two servo-driven
actuators, which allow two more axes of movement (A
and B). The wrist assembly has a unique cutting head
clamp that allows the operator to easily service the cutting head.
Specifications
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 mm
B-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10
A-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance
The components used in the wrist are protected from
everyday machine operation, and should provide

years of reliable operation without service. There are
no serviceable parts inside the wrist assembly and the
unit MUST NOT be opened except by Flow technicians.
Check the A and B motors for smooth rotation. There
should be no rough spots or excessive friction. Check

by holding onto the cutting head and rotating in all
directions.

realignment.
M-406 | 31

Wrist assembly exploded view
32 | M-406
CHAPTER 3
60K End Effectors
Mini on/off valve

The mini on/off valve, designed specifically for the DWJ,
is a pneumatically actuated valve that opens and closes
the high-pressure water line, thus controlling water flow
to the cutting head and nozzle.
The mini-valve has three distinct features:
Its small size allows it to mount directly above the
cutting head and tilt with the cutting head.

The low-mass actuator (0.5 lb) allows full acceleration
Maintenance
Recommended spares
To minimize maintenance downtime, at least one repair
kit for each on/off valve should be on hand.
711484-1
On/off valve repair kit
A-2185
Blue Lubricant
A-4689
Food grade o-ring lube (white)
and tilting of the cutting head.

The design of the valve-to-nozzle body connection
allows the valve to be oriented by the operator in any

radial direction to mate easily to high-pressure tubing
and other rigid components.
Specifications
Operating
water pressure. . . . . . . . 060,000 psi (04138 bar)
Water connection . . . . . . . . UHP in. tubing port
Valve weight . . . . . . . . . . . . . . . . . 1.5 lb (0.68 kg)
Recommended
water flow rate. . . . . . . . . 02 gpm (7.5 liter/min)
Shop air (dry or lubed) . . 60100 psig (4.16.9 bar)
Air connection . . . . . . . . . . . . . . . . . 6 mm air line
Configuration . . . . . . . normally closed, air to open
Response time*
Opening . . . . . . . . . . . . . . . . . . . . . . . 0.045 sec
Closing . . . . . . . . . . . . . . . . . . . . . . . . 0.100 sec
Tips for increasing the life of

on/off valve parts
The on/off valve is sensitive to debris in the high-
pressure water line that can damage the highpressure seal assembly. To increase life of the seal assembly (As well as high-pressure orifice life), Flow
recommends adding a 5-micron high-pressure in-line
water filter assembly (012832-2) to your system.
After replacing high-pressure plumbing or other
equipment on your high-pressure pump, flush the

system directly into the catcher tank before running
the high-pressure water through the on/off valve and
orifice. This will help minimize debris in the highpressure lines that could damage the valve or orifice.
Always follow the service procedures in this manual
when repairing the on/off valve to ensure proper assembly and installation of the valve.
* Note that response time will vary depending on

(1) length of the air line from the solenoid to the actuator, and (2) air pressure.
M-406 | 33

Troubleshooting the valve

There are two main categories of failure of the mini
on/off valve: leaking water and improper opening
and closing of the valve. Use the corresponding
chart to troubleshoot the problem.
When inspecting the mini on/off valve, pay attention to the utility connections and air linesthe
high-pressure water supply could be partially
blocked, or there could be bends, holes, or loose
connections in the air lines.
If causes other than those listed in the table are
found, please forward the information to the service department at FLOW (refer to MS-2266, Customer Service for contact information).
Importance of replacing all seal kit

components
Sometimes after troubleshooting, it may appear that
only one or two parts included in the seal kit need
to be replaced. However, you must replace all of
the seal kit parts at the same time for several
reasons:
All the components of the seal kit have similar
expected life times, so if one component fails,

the others are likely to fail very soon.
Failure of one component can cause extra stress
on the other components, increasing the likelihood that they will fail.
Installing the entire seal kit at one time will save
you from having to tear down the valve multiple

times, thus reducing total machine downtime.
34 | M-406
CHAPTER 3
60K End Effectors
Troubleshooting: valve is leaking

Continuous leakage from the barb fitting
SEE LOCATION 1 ON THE ILLUSTRATION ON THE PREVIOUS PAGE
Failed high-pressure
seal
Remove and replace the high-pressure seal assembly using kit 711484-1; see Servicing the
mini on/off valve.
Note: If this is a new valve, return the failed high-pressure seal assembly to FLOW technical service for evaluation.
A few drops leak from barb fitting at start up or when valve is cycled rapidly
SEE LOCATION 1 ON THE ILLUSTRATION
Worn high-pressure
seal
The high-pressure seal is beginning to wear out. It will start by leaking one drop every few
cycles, gradually increasing in frequency and volume of drops. The valve will continue to
function in this state for many thousands of cycles, until the drops form a steady stream.
The high-pressure seal assembly can be replaced at the operator's discretion until the leak
becomes a steady stream (see above). At that point it MUST be replaced.
Continuous leakage from the high-pressure water inlet

Poorly aligned connection between

high-pressure
tubing and valve
Open the high-pressure tubing connection. Make sure the tubing is aligned properly with
the port in the valve. Inspect the collet glanda minimum of three threads must be showing. Reassemble.
Loose connection
between highpressure tubing and
valve
Tighten high-pressure fitting between valve and tubing.
Failed high-pressure
valve body
Failure of the valve body is not common, so check the high-pressure seal assembly first. If
the valve still leaks continuously after replacing the high-pressure seal assembly, there may
be a problem with the valve body.
Remove the valve from the machine (see Servicing the mini on/off valve). Inspect the area
of the valve body near the high-pressure water inlet for a crack or damage to the inlet
cone. If there is a crack, order a replacement valve body (710866-1) and seal kit
(711484-1). If this is a new valve, return the failed valve to FLOW Technical Service for
evaluation.
Leakage from weep hole below high-pressure water inlet while valve is open
Poor connection between the nozzle

body and valve
body
1. Open the connection of the nozzle body to the valve body.

2. Inspect the location of the water body collar (710869-1) on the nozzle body. There should
be at least three to four threads exposed to ensure a proper seal from the nozzle body to
the valve seat.
3. If the large o-ring has extruded through the weep hole, remove and replace it
(A-0275-014).
4. Attach the pneumatic control line to the valve actuator assembly and turn on the air to
open the valve.
5. Re-assemble the nozzle body to the valve body. This high-pressure connection requires
about 7080 ft-lb (95110 N-m) of torque.
M-406 | 35

Leakage from nozzle tip while valve is closed and high-pressure pump is on
Debris in the
seat/poppet or
high-pressure seal
area
Remove and inspect the seat and poppet interface for debris such as metal shavings (see
Servicing the mini on/off valve). Remove any debris and re-assemble the valve.
If leakage persists, inspect the high-pressure seal for damage from debris. If there is damage
or continued leaking, replace the high-pressure seal kit (see Servicing the mini on/off valve).
Failed poppet/seat
Remove and inspect the seat (see Servicing the mini on/off valve). If there is erosion on the
edge of the seat bore or if there are radial cracks, replace the seal assembly.
Note that it is common to see a ring on the seat where the seat seals against the valve body
(picture). Unless there is evidence of severe galling, which can result from not using blue
lubricant (A-2185), this ring is normal and not a cause of valve failure.
Inspect the poppet tip for wear. If the poppet is worn, follow the service instructions to repair the valve and replace the high-pressure seal assembly.
36 | M-406
CHAPTER 3
60K End Effectors
Troubleshooting: Valve does not open

Low or no air
pressure
1. Make sure the shop air supply is on, properly connected, and the pressure at the actuator is
70-120 psig (4.8-8.3 bar).
2. Turn on the air and listen for leaks in the system. Check for kinks, breaks, and holes in the
air line.
3. Check the lights on the solenoid box (on the bridge) to make sure the solenoid is switching
on and off when commanded.
Lack of highpressure water
Make sure the pump is running. Check to see that all the hand valves leading to the on/off
valve are open.
Partially blocked
high-pressure water
1. Turn off the pump and close the hand valve.

2. Disconnect the high-pressure water line from the valve, aim it into the tank, and secure it.
3. Open the hand valve and turn the high-pressure pump back on.
Watch to make sure there is a steady stream of high-pressure water shooting into the tank.
If the stream is erratic, there may be a blockage in the lines.
4. Check all high-pressure in-line water filters in the system. If necessary, replace with the appropriate new filter element. (See manual M-127, Small High-Pressure Components.
Failed actuator
Watch the top of the actuator while manually switching the air on and off with the
high-pressure water on. If the air port on top of the actuator does not move up and down,
there is a problem with the actuator.
Remove the mini-actuator from the air line, valve, and machine. Order a new actuator assembly (710875-1) and return the assembly to Flow Technical Service for evaluation.
FLOW TECHNICAL SERVICE ONLY:
Dissassemble the actuator. Make sure the u-cup seals are installed in the correct orientation
and are free from kinks or folds. Remove and replace the actuator seals as required. Clean
all parts. If the internal springs are rusted, replace them. Lube internal parts and reassemble
the actuator. If it still is not working, replace it. Check the customer's air line to make sure it
is providing dry, lubed air.
Damaged highpressure valve seal
If the air port on top of the actuator moves up and down, but the valve still does not open
(and you have already checked for little or no air pressure), there may be a problem with
the valve seal.
If the on/off valve has been operated while the barb fitting has been continuously leaking,
the high-pressure seals may be melted and stuck in the valve body.
Replace the seal assembly (see Servicing the mini on/off valve).
Controller
command
Make sure the controller is signaling the valve to open.
M-406 | 37

Troubleshooting: Valve does not close

Valve is leaking
water
Determine where the valve is leaking. Follow the tips in the first troubleshooting table,
Valve is leaking, to diagnose the problem.
Air is not turning off
Try manually switching the air on and off or disconnecting the air line to see if the valve
will close. There may be a problem with your software program or controller command to
turn the air off.
Damaged highpressure valve seal
If the air port on top of the actuator moves up and down, but the valve still does not open
(and you have already checked for little or no air pressure), there may be a problem with
the valve seal.
If the on/off valve has been operated while the barb fitting has been continuously leaking,
the high-pressure seals may be melted and stuck in the valve body.
Replace the seal assembly (see Servicing the mini on/off valve).
Actuator is not closing Remove the valve assembly from the machine and remove the actuator from the valve (see
Servicing the mini on/off valve). Check the operation of the actuator without the valve or
high-pressure water.
The piston should move up and down, but slower than when used with high-pressure water
If the piston does not move, there is a problem with the actuator
Return the actuator assembly to Flow for evaluation and order a new actuator assembly
(710875-1).
FLOW TECHNICAL SERVICE ONLY:

Dissassemble the actuator. Make sure the U-cup seals are installed in the correct orientation and are free from kinks or folds. Remove and replace the actuator seals as required.
Clean all parts. If the internal springs are rusted, replace them. Lube internal parts and reassemble the actuator. If it still is not working, replace it. Check the customer's air line to
make sure it is providing dry, lubed air.
38 | M-406
CHAPTER 3
60K End Effectors
Servicing the valve

You will need these tools and parts for any of the mini
on/off valve service procedures:
711484-1 Mini on/off valve repair kit
A-2185
Blue Lubricant
A-4689
Removing the valve

WARNING
Shut down the system and bleed all high-pressure
from the system. Turn off the high-pressure water
and high-pressure water pump. Close the hand valve
between the pump and the cutting head.
Set of crescent wrenches (standard size)

Soft-jaw vise
Work bench
1. Turn off air to the valve and disconnect the pneumatic line.
2. Disconnect the high-pressure plumbing from the
valve body.
3. Open the DWJ clamp and remove the entire cutting
head assembly, including the valve and actuator. Take
the assembly to a clean workbench for any repair
procedures.
M-406 | 39

Repairing the valve

4. Apply shop air (80 psi min) to the valve actuator assembly to open the valve.
8. Place the 3 16 -in. wooden dowel (from the valve repair

kit) against the poppet tip and push it out from the
valve body.
5. Place the assembly in the soft-jaw vise; unscrew the

valve body nut from the valve body. This will separate
the mini valve and actuator from the cutting head
and expose the poppet seat. Once the connection is
completely loose, turn off the air to close the valve.
6. An o-ring helps hold the poppet seat in place. Remove the o-ring and the poppet seat should fall out
from the valve body. Discard the seat and o-ring.
Note: If the seat does not fall out when you tap the
nozzle body, use your finger or the wooden dowel to
help loosen the seat.
7. Unscrew the valve body from the actuator assembly.
Set the actuator assembly aside.
The bearing, high-pressure seal, and backup ring

should come out with the poppet. If not, push the
bearing, seal, and backup ring out of the valve body
in the same direction as you pushed the poppet. Discard the poppet, seal, o-ring, and backup ring.
9. Clean any foreign material from the inside and outside of the valve body.
10. Apply a thin film of white food grade o-ring lube
(A-4689) to the new poppet, o-rings, seal, bearing,
and backup ring (from kit 711484-1)
11. Put together the new seal assembly.
a. Slide the bearing onto
the poppet.
b. Place the small highpressure o-ring on the
high-pressure seal.
c. Push the seal onto the
poppet with the o-ring
toward the point of the
poppet.
d. Slide the backup ring
into place against the
high-pressure seal.
The seal assembly should be approximately
centered on the poppet.
40 | M-406
CHAPTER 3
60K End Effectors
12. Slide the poppet seal assembly into the actuator end
of the high-pressure valve body, pointed end first.
Reinstalling the valve

WARNING
Make sure the high-pressure pump is OFF.
CAUTION
Opening the valve before tightening this connection reduces the
possibility of galling between the poppet and seat interface and
reduces the force required as you are not working against the
high spring force of the actuator.
17. Attach the pneumatic control line to the valve actuator assembly and turn ON the air to open the
valve.
18. With the valve in the open position, align the valve
with the high-pressure tubing so that the weep tube
and high-pressure tubing point toward the front of
the machine.
13. Apply a small amount of Blue Lubricant (A-2185) to
the threads of the actuator. Reinstall the actuator assembly to the valve body.
14. Apply a small amount of Blue Lubricant to both sides
of the new poppet seat. Install the poppet seat into
the valve body. Push the o-ring into the groove to
hold the poppet seat in place.
15. Apply a small amount of Blue Lubricant to the external threads of the valve body and thread it onto the
nozzle body by tightening the valve body nut. Leave
this connection hand-tight for now.
19. Tighten the connection between the nozzle body and

the valve body nut to 3540 ft-lb (4754 N-m).
Once the connection is tight, turn off the air to close
the valve.
Note: Opening the valve before tightening this connection reduces the possibility of galling between the
poppet and seat interface and reduces the force required as you are not working against the high spring
force of the actuator.
20. Attach the high-pressure tubing to the valve. Be
careful not to over-torque this connection.
21. Open the hand valve between the high-pressure
water source and the cutting head.
Turn on the high-pressure water source and slowly raise
the pressure while checking for leaks. Manually actuate
the valve a few times to make sure it is operating correctly.
16. Reinstall the cutting head and on/off valve assembly

to its original location on the machine by clamping
the cutting head in place.
M-406 | 41


The DWJ cutting head has the same purpose and functionality as Flows standard PASER ECL Plus system,
however, it has been modified to provide the superior
cutting precision necessary for DWJ applications.
The cutting head assembly includes the nozzle body, orifice, mixing chamber, collet and nozzle nut, mixing tube,
and Integrated spray shield and blast disk.
How it works
When the mini on/off valve is opened, high-pressure water flows through the orifice assembly into the mixing
chamber, where it creates an area of partial vacuum.
The vacuum draws a metered flow of abrasive through
the abrasive delivery line, where it combines with the
water to create a high-energy abrasivejet cutting stream.
This stream exits the cutting head through the mixing
tube at a velocity of up to 3000 ft/sec (914 m/s). After
cutting, the residual energy of the abrasive stream (up to
70% of nozzle tip energy) is contained and dissipated by
a catcher.
Orifice assembly
High precision mixing chamber

The mixing chamber holds the orifice assembly and the
mixing tube in alignment. It also provides a place for the
abrasive and water to mix. The precision-machined
shoulder serves as a stop for the mixing tube. There are
no carbide pins or inserts used in the cutting head.
The mixing chamber is where the abrasive and water
mix. The mixing chamber has two abrasive inlets, so one
will be cose to the metering valve when tightened. In
most cutting configurations, only one inlet is used. Be
sure to cover the unused inlet with the provided plastic
cap.
Collet and nozzle nut

The high-precision collet precisely centers the mixing
tube in the cutting head. The conical shape is matched
to the machined conical shape of the downstream region of the cutting head body. This ensures a precise axial and radial registration of the mixing tube in the
cutting head. An o-ring built into the nut seals the collet
to the mixing tube. This creates the proper suction for
the abrasive and, in particular, for use with vacuum
assist.
A precision orifice mount in the top of the high-precision mixing chamber secures and aligns the high-pressure orifice assembly. Standard PASER ECL Plus orifice
assemblies are used with the DWJ.
42 | M-406
CHAPTER 3
60K End Effectors
Mixing tube
The mixing tube focuses and accelerates the abrasive
that is entrained in the water stream. The PASER ECL
Plus mixing tube is designed with a ring on the upper region, which precisely registers the mixing tube in the
cutting head. This ensures that the abrasivejet stream is
centered in the mixing tube.
A simple way to install the mixing tube is to hold the retaining nut in your palm, snap in the collet, then drop in
the mixing tube and let it extend between your fingers.
Screw this assembly onto the mixing chamber.
Integrated spray shield and blast disk

The blast disk protects the collet, nut and other precision
components from the reverse spray of the jet while
piercing material. The spray shield protects the operator
and the rest of the components of the DWJ wrist while
cutting.
The shield snaps into the nut and the blast disk fits into
the shield. They can be replaced individually or together
when worn through. Flow recommends that you keep
two of each on hand and replace them as soon as necessary. This will help prevent excessive wear of the more
expensive precision components in the DWJ system.
Servicing the cutting head components

Refer to the manual M-359, PASER ECL Plus for orifice
and mixing tube replacement procedures.
M-406 | 43

Notes
44 | M-406
CHAPTER 4
94K End Effector

Two 94K end effectors are available for the Mach 3b
and Mach 4b Series System: Standard and Dynamic.
Both end effectors use the PASER ECL Plus cutting head.
Standard end effector

The standard end effector uses a cutting head that is
mounted perpendicular to the cutting envelope.
The standard end effector has four main components:
Z-axis
On/off valve
Height sensor
Dynamic Waterjet End Effector

The Dynamic Waterjet (DWJ) is a wrist tilting end
effector designed for flat stock machines. Its revolutionary design provides a better way to correct two common
drawbacks to abrasivejet cuttingtaper and inside corner kickback.
Slowing down the cutting speed used to be the best way
to reduce these effects. The DWJ cutting head provides
a better way. Tilting the head removes the taper from
one side of the cut, leaving a vertical cut on the side of
the part. Tilting the jet tip into the direction of travel reduces drag, so cutting speeds on inside corners can often be increased without damaging the underside of the
part.
The DWJ end effector has five main components:
Z-axis
Mini-wrist
On/off valve
Height sensor
These are illustrated and described in this chapter.

Tips and guidance on using the DWJ effectively can be
found in manual MS-2276, How To Be Successful With
Dynamic Waterjet.
M-406 | 45

Z-axis
Work envelope
Tilting a cutting head influences the overall travel of an
X,Y system. A tilting head with thhe DWJ kinematics
uses X,Y,Z-axes travel to compensate for variation in the
tool center point. Depending on maximum tool length,
the maximum travel of the X- and Y-axes is decreased by
about 4 in. (50 mm).
The available travel of the Z-axis is influenced by tilting
the cutting head and by mixing tube length. It is important when using the DWJ to consider what mixing tube
will be used. With DWJ on the system, the minimum
tool length must be able to reach the catcher tank grid
when the head is tilted to the maximum A- and B-axis
angles.
The FlowMaster screen automatically shows the available
cutting envelope.
Maintenance
The components used in the Z-axis are protected
from everyday machine operation, and should provide years of reliable operation without servicing.
There are no serviceable parts inside the Z-axis and
the unit must never be opened except by Flow technicians.
consult Flow Technical Service for information on realignment.
46 | M-406
CHAPTER 4
94K End Effectors
DWJ wrist assembly
Maintenance
The DWJ wrist assembly is powered by two servo-driven

actuators, which allow two more axes of movement (A
and B). The wrist assembly has a unique cutting head
clamp that allows the operator to easily service the cutting head.
The components used in the wrist are protected from
Specifications
Check the A and B motors for smooth rotation. There
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 mm
B-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10
A-motor rotation . . . . . . . . . . . . . . . . . . . . . . . 10
everyday machine operation, and should provide

years of reliable operation without service. There are
no serviceable parts inside the wrist assembly and the
unit MUST NOT be opened except by Flow technicians.
should be no rough spots or excessive friction. Check
by holding onto the cutting head and rotating in all
directions.

realignment.
M-406 | 47

On/off valve
Maintenance
The on/off valve, designed specifically for the DWJ, is a

pneumatically-actuated valve that opens and closes the
high-pressure water line, thus controlling water flow to
the cutting head and nozzle.
Recommended spares
The on/off valve has three distinct features:

Its size allows it to mount directly above the cutting
head and tilt with the cutting head.

The low-mass actuator (0.5 lb) allows full acceleration
and tilting of the cutting head.

The design of the valve-to-nozzle body connection
To minimize downtime and reduce the need for rush orders, you should have at least one repair kit for each
on/off valve.
014988
Seal kit
A-2185
Blue Lubricant
A-4689
014630-1
Plunger tool
014631-1
Guide tool
allows the valve to be oriented by the operator in any

radial direction to mate easily to high-pressure tubing
and other rigid components.
Tips for increasing the life of on/off valve parts
Specifications
Operating
water pressure. . . . . . . . 087,000 psi (06000 bar)
Water connection . . . . . 87K UHP -in. tubing port
Valve weight . . . . . . . . . . . . . . . . . 1.5 lb (0.68 kg)
Recommended
water flow rate. . . . . . . . . 02 gpm (7.5 liter/min)
Shop air (dry or lubed) . . 60100 psig (4.16.9 bar)
Air connection . . . . . . . . . . . . . . . . . 6 mm air line
Configuration . . . . . . . normally closed, air to open
Response time*
Opening . . . . . . . . . . . . . . . . . . . . . . . 0.045 sec
Closing . . . . . . . . . . . . . . . . . . . . . . . . 0.100 sec
After replacing high-pressure plumbing or other
equipment on your high-pressure pump, flush the

system directly into the catcher tank before running
the high-pressure water through the on/off valve and
orifice. This will help minimize debris in the highpressure lines that could damage the valve or orifice.
Always follow the service procedures in this manual
when repairing the on/off valve to ensure proper assembly and installation of the valve.
Servicing the on/off valve

Refer to the manual M-393, Hyperpressure Small
High-pressure Components for troubleshooting and service procedures.
* Note that the response time will vary depending on

(1) length of the air line from the solenoid to the actuator, and (2) air pressure.
48 | M-406
CHAPTER 4
94K End Effectors

The DWJ cutting head has the same purpose and functionality as Flows standard PASER ECL Plus system,
however, it has been modified to provide the superior
cutting precision necessary for DWJ applications.
The cutting head assembly includes the nozzle body, orifice, mixing chamber, collet and nozzle nut, mixing tube,
spacer, and Integrated spray shield and blast disk.
How it works
When the on/off valve is opened, high-pressure water
flows through the orifice assembly into the mixing chamber, where it creates an area of partial vacuum. The vacuum draws a metered flow of abrasive through the
abrasive delivery line, where it combines with the water
to create a high-energy abrasivejet cutting stream.
This stream exits the cutting head through the mixing
tube at a velocity of up to 3600 ft/sec (1100 m/s). After
cutting, the residual energy of the abrasive stream (up to
70% of nozzle tip energy) is contained and dissipated by
a catcher.
Orifice assembly
High precision mixing chamber

The mixing chamber holds the orifice assembly and the
mixing tube in alignment. It also provides a place for the
abrasive and water to mix. The precision-machined
shoulder serves as a stop for the mixing tube. There are
no carbide pins or inserts used in the cutting head..
The mixing chamber is where the abrasive and water
mix. The mixing chamber has two abrasive inlets, so one
will be cose to the metering valve when tightened. In
most cutting configurations, only one inlet is used. Be
sure to cover the unused inlet with the provided plastic
cap.
Collet and nozzle nut

The high-precision collet precisely centers the mixing
tube in the cutting head. The conical shape is matched
to the machined conical shape of the downstream region of the cutting head body. This ensures a precise axial and radial registration of the mixing tube in the
cutting head. An o-ring built into the nut seals the collet
to the mixing tube. This creates the proper suction for
the abrasive and, in particular, for use with vacuum
assist.
A precision orifice mount in the top of the highprecision mixing chamber secures and aligns the highpressure orifice assembly. Standard PASER ECL Plus orifice assemblies are used with the DWJ.
M-406 | 49

Mixing tube
The mixing tube focuses and accelerates the abrasive that
is entrained in the water stream. The PASER ECL Plus
mixing tube is designed with a ring on the upper region,
which precisely registers the mixing tube in the cutting
head. This ensures that the abrasivejet stream is centered
in the mixing tube.
A simple way to install the mixing tube is to hold the retaining nut in your palm, snap in the collet, then drop in
the mixing tube and let it extend between your fingers.
Screw this assembly onto the mixing chamber.
Integrated spray shield and blast disk

The blast disk protects the collet, nut and other precision
components from the reverse spray of the jet while piercing material. The spray shield protects the operator and
the rest of the components of the DWJ wrist while
cutting.
The shield snaps into the nut and the blast disk fits into
the shield. They can be replaced individually or together
when worn through. Flow recommends that you keep
two of each on hand and replace them as soon as necessary. This will help prevent excessive wear of the more
expensive precision components in the DWJ system.
50 | M-406
CHAPTER 4
94K End Effectors
Servicing the cutting head components

Orifice
If you are experiencing loss of cutting power or degraded
jet quality, check the high-pressure orifice assembly for
evidence of blocking debris or damage.
During indirect inspection, check for evidence of erosion,
wear, or other damage to the orifice assembly retainer
surface. The orifice assembly must sit squarely against the
retainer surface for correct alignment with the mixing
tube.
7. Apply a very thin film of Blue Lubricant at the top of

the orifice assembly. Use a clean, lint-free applicator
(such as a swab or small paintbrush).
CAUTION
The amount of Blue Lubricant must be small enough
that it cannot flow toward the bore of the orifice.
8. Make sure the seating surface in the mixing chamber is

free of abrasive, then drop the orifice assembly into
the body, shaking the body until the assembly drops
into the taper.
9. Apply Blue Lubricant to the pilot diameters and
threads of nozzle body. Attach cutting head body to
nozzle body. Using a torque wrench with a crows foot
attachment, tighten to 3035 ft-lb.
CAUTION
Do not over-tighten the cutting headit will
damage mating surfaces, such as the nozzle body.
It can also damage the orifice mount (by forcing
the mount out of round, or by flattening it.)
Such damage is not covered by warranty.
10. Reattach the abrasive feed line and check for leaks.
Notes:
Changing the orifice
CAUTION
When changing orifices or otherwise working on highpressure components, it is critical that you use backup wrenches.
Excessive torque on the cutting head can damage
the wrist motors. Such damage will void your warranty.
The nozzle body, mixing chamber, orifice assembly,
all work surfaces, and the hands of the service
technician must be clean and free from dirt and
abrasive when working with the orifice assembly.
If the cutting head leaks with 35 ft-lb of torque, take it
apart and find out whats wrong. Contamination of the

nozzle components will most likely be the problem. A
complete and thorough cleaning of hands and components will be required.
Hand-tightening the nozzle body is not sufficient. It
will result in leaks, which will ultimately damage nozzle body components.
Blue Lubricant will readily collect dust, dirt,

and abrasive. Any contamination of the orifice
assembly will most likely cause the nozzle to leak.
1. Turn the high-pressure pump off and bleed all pressure

from the system.
2. Pull firmly on the abrasive feed line to remove it from
the cutting head.
3. Open the cutting head clamp.
4. Using one wrench on the nozzle body and one on the
mixing chamber, loosen the connection between the
two parts.
5. Once separated, store the nozzle body in the feature
on top of the cutting head clamp. Take the mixing
chamber to a workbench.
6. Tap the body upside down on a table to remove the
orifice assembly. If necessary, lightly pry on the mount
with a screwdriver.
M-406 | 51

Mixing tube
Notes:
Inspecting the mixing tube
For the best cutting accuracy, inspect the mixing tube

once per shift or before starting a new job in order to
monitor and limit ID growth. This is very important for effective and efficient use of the DWJ.
Tools required
Pin gauges, or a dial caliper
Procedure
Remove the mixing tube from the mixing chamber body:

CAUTION
The mixing tube is made from brittle carbide and is
easily damaged. Do not bend it, drop it, or twist it.
2. Inspection could also reveal some of the conditions

listed below. Any of these are acceptable as long as
they do not result in degraded abrasivejet stream
appearance or performance.
1. Inspect the mixing tube for obvious cracks, chips, erosion, and other damage.
Replace the mixing tube for any of these conditions:
Obvious, off-center wear at the nozzle exit end

ID.
Chips in the downstream end, outside edge of
the nozzle that originate at the outside diameter,
leaving less than 0.020 in. nozzle wall.
Cracks that extend radially from the nozzle
ID to OD or extend down the length of the
nozzle.
Chips in either end of the nozzle that originate at
the inside diameter. Do not confuse normal wear
(concentric or off-center) of the upper end of the
mixing tube with chipping.
The nozzle tip exit ID is worn enough to degrade
cutting accuracy and performance below acceptable levels:
For DWJ cutting: 0.010 inch (0.25 mm)
greater than original size
For non-DWJ cutting: 0.02 inch (0.5 mm)
greater than original size
Imperfections other than changes of color or
scoring in the area covered by the collet.
Some obvious erosion of the upper end of the

tube is acceptable, as long as wear does not allow water and abrasive to migrate between the
tube OD and the body ID or result in degraded
abrasivejet stream appearance or performance.
Use nozzles that are too worn for DWJ cutting
for parting material and other non-precision cutting jobs (such as parting materials), rather than
using new, expensive nozzles for these jobs.
Discoloration or surface scoring.

Erosion on the cone in the upper end of the mixing tube that does not affect the tube-to- body
mating or reduce the nozzle wall to less than
0.020 in.
Scoring or scratching of the exposed length of
the mixing tube.
Grooves, spirals or other erosive wear of the tube
ID that does not affect the performance of the
abrasivejet stream or excessively increase the
mixing tube exit end ID.
If inspection does not reveal any unacceptable conditions,

reinstall the mixing tube.
Changing the mixing tube
No tools are necessary for this procedure.

Procedure
1. Make sure the intensifier pump is off and all pressure

bled from the system.
WARNING
Shut down the system and bleed all high-pressure
from the system. Turn off the high-pressure water
and high-pressure water pump. Close the hand valve
between the pump and the cutting head.
2. Remove the retaining nut and mixing tube together.

3. Put the end of the mixing tube on a pliant surface such
as wood or plastic. Press the retaining nut down and
remove it from the mixing tube, then pull out the
tube.
4. Install the collet into the retaining nut, install the new
mixing tube into the collet from the collet side, then
install the collet/mixing tube assembly into the cutting
head.
52 | M-406
CHAPTER 5
X,Y Table
The X,Y frame is a self-supporting welded rectangular
tube construction, with adjustable feet to allow the frame
to be aligned. Drives and linear units are directly
mounted on the frame.
The cutting heads move in X, Y, and Z directions. The
Y-direction is parallel to the base rail; the X-direction is
parallel to the bridge.
The X-motion is generated by moving the bridge on the
linear units (buses) mounted in parallel. The X, Y, and Z
axes are driven via ball screws. The ball screws as well as
other moving parts of the linear units are protected by
bellows against humidity and soiling.
The axes must be homed before use, and the Y,A,B
axis needs to be homed before the X,Y. Refer to the

FlowMaster manual for information on homing.
M-406 | 53

Maintenance schedules
The following inspection schedules are based on a
16-hour production day, 5 days a week, with the equipment located in a suitable environment. Changes to
these schedules may be necessary, depending on actual
production hours and equipment environment.
The following covers only the X,Y machine. Be sure to
refer to pump inspection and maintenance schedules located in other component manuals shipped with the
system. These are listed at the beginning of this manual.
Inspection
Daily inspection
Clean all exposed rails, ways, and cylinder rods. Lu-
bricate with a light coating of aluminum complex

base grease.
Clean all debris from machine and part holding/cut-
Weekly inspection
Lubricate all rail and way bearings.
Clean all linear drive lead screws.
Clean the bellows of the linear units with a soft brush.
Quarterly inspection
Remove all debris from equipment and clean thor-
oughly. Check all hoses, tubing, fittings, and electrical

lines. Replace any worn or chafed lines.
Check condition of wire ways, traveling cables, and
cable track. Clean and lubricate joints as necessary

with light machine oil.
Clean all rails and ways thoroughly. Examine closely
for any defect, damage, or excessive wear. Repair or

replace as required.
Check the general condition of the equipment. Re-
pair or replace lamps, indicating gauges, and switches

as required.
ting fixtures.
Check part clamp linkages, part clamps, locating pins,
proximity switches, limit switches, and air/electrical

lines on the part holding/cutting fixture. Repair or replace as needed.
Make sure electrical enclosures and junction boxes
are closed and secure.

Individually activate all emergency stop devices, in-
cluding E-stop buttons, floor mats, and light curtains.

Check for proper operation and lock out any machine that has malfunctioning emergency stop
devices.
54 | M-406
CHAPTER 5
X,Y Table
Recommended lubricants
Use the following lubricants for X,Y components. Refer to
the pump manual and PASER manuals for recommended
lubricants for these components. Use only a hand operated, low volume grease gun when applying lubricants.
For X,Y,Z ball nut and ball screw

Lubriplate L0083-035
For X,Y,Z linear bearings

Lubriplate L0083-035
CAUTION
FLOW does not recommend using any other type
of bearing grease. Mixing can cause the grease
to solidify, reducing bearing life up to 75%.
Recommended cleaners
For lead screws and rails
CRC Industries, Technical Grade 3-36. Spray on a
light coat and allow to penetrate residue. Wipe clean

using a lint-free cloth. Repeat as necessary.
For bellows cover, painted surfaces

Johnson Envy instant cleaner (or equivalent). Spray
foam evenly over surface, wipe clean with cloth,

sponge, or paper towel. Repeat as necessary.
M-406 | 55

Troubleshooting the X,Y table

1. Y-axis is not true
Contact FLOW Technical Service.
2. X-axis is not true
Set up a precision square, and run the X in and out. Contact FLOW Technical Service, if necessary.
3. X,Y axis locked in corner or will not jog
1.
2.
3.
4.
5.
Exit all programs.

Turn machine power off and wait for 10 seconds.
Turn power back on and wait for PC boot-up to complete.
Push or pull X or Y or both axes out of corner or current position about 6 in.
Return to FlowCUT, select Run Machine, and then home the machine. Jog the axis.
If this does not fix the problem, call FLOW Technical Service.
4. Rough cuts are observed
Incorrect clearance.
1.
2.
3.
4.
Check the clearance between the pump/motor plate and the frame.
Make sure the machine frame is level and steady.
Make sure the catcher tank and grate are secure
Make sure your workpiece is secure.
5. X-axis makes a rough binding noise
X axes rails are not aligned.
Move the carriage and feel or listen to where the binding occurs. Realign the
rails. When correctly aligned, tighten bolts.
6. No pressure display
1.
2.
Check wiring.
Verify power is ON.
Input display out of range.
1.
2.
Check unit scaling.

Check for electrical disturbance.
Loss of data set-ups.
1.
2.
3.
Check data set-ups.

Disconnect and reconnect power.
1.
2.
3.
Check data set-ups.

Disconnect and reconnect power.
Power off, improperly

connected, or brown-out.
7. "......" pressure in display
8. Pressure display wanders
Loss of data set-ups
56 | M-406
CHAPTER 5
X,Y Table
9. Jittery pressure display
Electrical noise in process or

line.
1.
2.
3.
Increase digital filtering.

Increase display rounding increment.
Re-route signal wires.
Process inherently unstable.
Dampen process to eliminate oscillations.
10. "ULULUL" in pressure display
Input underload (negative

overload).
Check input levels.
11. "OLOLOL" in pressure display.
Input overload.
Check input levels.
12. Servomotor does not start
Power not connected.
1.
2.
Correct the power circuit.

Check fuses.
Loose connection.
Tighten any loose parts.
Connector external wiring

incorrect.
Refer to connection diagram and correct wiring.
Servomotor disconnected.
Reconnect wiring or replace cable. Cable may be broken in cat-track.
Alarm tripped.
Reset servo amplifiers.
13. Servomotor moves instantly and then stops
Encoder wiring incorrect or

broken.
Replace cable or connectors.
14. Servomotor speed unstable
Wiring connection to motor

defective.
Tighten any loose terminals or connectors.
15. Servomotor overheated
Ambient temperature too high.
Reduce ambient temperature to 40C (104F) max.
Servomotor surface dirty.
Clean dust and oil from motor surface.
Overloaded.
Run under no load. If looks fine, look for mechanical binding.
16. Abnormal noise
Mechanical mounting incorrect
1.
2.
3.
Bearing defective.
Check noise and vibration near bearing.

Call Flow Technical Service.
Machine causing vibrations.
Call Flow Technical Service.
Tighten mounting screws.

Center coupling.
Balance coupling.
M-406 | 57

Notes
58 | M-406
CHAPTER 6
Engineering Drawings
The following drawings are provided with this manual (pump drawings are located with the pump manual). Please
note that drawings are provided for reference only. Drawings and part numbers can become obsolete as a part of
Flows ongoing product improvement. If part numbers are replaced by new numbers, Flow Customer Service will
inform you when you order new parts.
Pumps
The complete pump drawing package is located in the pump manual shipped with the equipment. For 60K systems,
refer to manual M-397 HyPlex Hybrid, M-349 50i-S, or M-351 100i-D. For 94K systems, refer to manual M-390
HyperJet 94i-S & HyperJet 94i-D
60K pumps
94K pumps
See the pump manual or drawings tab on the CD-ROM.
See the pump manual or drawings tab on the CD-ROM.
013670-1
013480-1
046745-X
020143-1
(integrated)
020144-1
(integrated)
042570
(standalone)
042210
(standalone)
50i-S intensifier pump

100i-D intensifier pump
30/50 hp HyPlex Hybrid pump
CE HyperJet 94i-S pump assembly

CE HyperJet 94i-D pump assembly
CE HyperJet 94i-S pump assembly
CE HyperJet 94i-D pump assembly
M-406 | 59

Plumbing
60K plumbing assembly
044560-X Rev. 01
60K high-pressure plumbing assembly
Part #
Pump
Heads
# Whips
044560-1, -3, -5
30 HyPlex Hybrid or
50 i-S
Single
044560-2, -4, -6
30 HyPlex Hybrid or
50 i-S
Dual
044560-7, -9
50 HyPlex
Single
044560-8, -10
50 HyPlex
Dual
044560-11, -13, -15
100 i-D
Single
044560-12, -14, -16
100 i-D
Dual
94K plumbing assembly

044731-X Rev. 01
94K high-pressure plumbing assembly
Part #
Pump
Heads
# Whips
044731-1, -3, -5
HyperJet 94i-S
Single
044731-2, -4, -6
HyperJet 94i-S
Dual
044731-7, -9, -11
HyperJet 94i-D
Single
044731-8, -10, -12
HyperJet 94i-D
Dual
60 | M-406
CHAPTER 6
End effectors
60K end effectors
94K end effectors
Dynamic Waterjet XD
045150-1
DWJ-XD wrist assembly
045160-1
DWJ-XD cutting head assembly
014660-1
Low profile on/off valve assembly
Dynamic Waterjet
040150-2
IFB DWJ wrist assembly
014660-1
On/off valve assembly
020695-1
Cutting head assembly
043994-1
PASER ECL cutting head assembly
Dynamic Waterjet
043339-1
IFB DWJ cutting head assembly
046427-1
IFB DWJ wrist assembly
710870-1
On/off valve assembly
712262-1
PASER ECL cutting head assembly
Non-Dynamic Waterjet
043330-1
IFB single cutting head assembly
043331-1
Dual cutting head assembly (24 in.)
043331-2
043331-3
Non-Dynamic Waterjet
043332-1
IFB single cutting head assembly
043333-1
043333-2
043333-3
M-406 | 61

X,Y assemblies
For 60K and 94K Mach 3b and Mach 4b Series systems
Bases and bridges

XY module
Base assembly
Bridge assembly
044429-1
043908-1 1.25M base
044248-1 1.25M bridge
044430-1
043910-1 2.5M base
044248-1 1.25M bridge
044431-1
043912-1 3.05M base
044249-1 2M bridge
044917-1
044872-1 4M base
044249-1 2M bridge
044433-1
043916-1 7.32M base
044249-1 2M bridge
Cover options
044440-1
044440-6
044440-2
044440-7
044440-3
044440-8
044440-4
044440-5
Metal-single (1.25M base cover package only)

Metal-dual (1.25M base cover package only)
Metal-single (60K 2.5M base cover package only)
Metal-dual (60K 2.5M base cover package only)
Metal-single (not available for 1.25M base)
Metal-dual (not available for 1.25M base)
Plastic-single (not available for 1.25M base)
Plastic-dual ((not available for 1.25M base)
Catchers
Catcher dimensions are bridge x base
-1 U.S., -2 Asia, -3 Europe
044292-X
047820-X
044285-X
047885-X
044297-X
047895-X
044180-X
047810-X
044320-X
1.3x1.3M catcher
1.3x1.3M catcher (for DWJ-XD equipped system)
2.5x1.3M catcher
2.5x1.3M catcher (for DWJ-XD equipped system)
3x2M catcher
3x2M catcher (for DWJ-XD equipped system)
4x2M catcher
4x2M catcher (for DWJ-XD equipped system)
7.3x2M catcher
Note: When ordering a new, complete catcher assembly, order one of the following part numbers. These drawings are not included on the CD.
62 | M-406
CHAPTER 6
Electrical
The electrical wiring diagram for your equipment can be found in the electrical enclosure.
See engineering drawing for dashnumber identification
Assemblies
044052-1
044444-X
Electrical assembly
60K soft starter kit
Console modules
044393-1
044393-2
Console module (25 foot cable)

Console module (50 foot cable)
Transformers
044386-1
A-01068-X
Transformers kit
Optional transformer
Installation
046472-1
047539-1
046473-1
047961-1
046474-1
047960-1
046475-1
047962-1
046476-1
047971-1
047378-1
047972-1
4020
4020
1313
1313
2513
2513
3020
3020
7320
7320
7320
7320
Global IFB
Global IFB (for DWJ-XD equipped system)
Global IFB
Global IFB
Global IFB
(Single Zone) Global IFB
(Single Zone) Global IFB (for DWJ-XD equipped system)
(Double Zone) Global IFB
(Double Zone) Global IFB (for DWJ-XD equipped system)
Note: Installation drawings are intended for use by Flow Technical Services personnel only.
These drawings are not included on the CD.
M-406 | 63

Kits
Miscellaneous service parts

For 60K and 94K systems
Consumables
60K
011767-X
042218-1
042218-2
50i-S & 100i-D consumable parts

HyPlex Hybrid minor maintenance kit
HyPlex major maintenance kit
94K
040467-1
040467-2
HyperJet 94i-S consumable parts

HyperJet 94i-D consumable parts
Spares
60K
010558-3
94K
020070-1
C-2217-1 Intensifier assembly fixture (60K only)

Bolts to a workbench; use for assembling the intensifier on a
workbench.
A-2185 Blue Lubricant

Anti-galling compound for all threaded high-pressure
connections.
A-4689 White Food Grade O-ring Lube

Use as a lubricant for all o-rings that come in contact
with water.
200006 Parker Super O Ring Lube

Spare 60K intensifier
Use as a lubricant for all o-rings that come in contact

with hydraulic oil.
MS-2258 Intensifier Pump Maintenance

and Service Log
Spare 87K intensifier
One copy is provided on the CD-ROM. Purchase

additional copies for subsequent years.
Tools
60K
012068-1
007140-1
HyPlex Hybrid tool kit

50i-S & 100 i-D tool kit
94K
040226-2
Complete 87K tool kit
Operator convenience kit

Standard/required for Mach 3b and Mach 4b Series
systems equipped with a Dynamic Waterjet XD end
effector.
017137-1
Low profile clamp kit
017137-2
Low profile bracket clamp kit
047311-X
Spray containment kit
(for DWJ-XD equipped system)
A-24300-1
Material removal tool
A-21703-1
Battery-powered laser pointer
64 | M-406

m406 - en Mach 3b and 4b Series

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MACH 3B SERIES

M-406 | Rev. B | January 2010

Mach 3b and Mach 4b Series System

Flow International Corporation

Mach 3b and Mach 4b Series System

Chapter 3. 60K End Effectors

Flow International Corporation

Mach 3b and Mach 4b Series System

Chapter 5. X,Y Table

Flow International Corporation

Warnings, cautions, & notes

Flow International Corporation

Mach 3b and Mach 4b Series System

Flow International Corporation

Equipment Description & Operation

Flow International Corporation

Mach 3b and Mach 4b Series System

FlowMaster PC-based controller

Integrated ultrahigh-pressure pump

WaterVeyor abrasive removal system

There are five available pumps for the Mach 3b and

The Waterveyor is designed to remove spent abrasive

50i-S or 100i-D intensifier pump

HyPlex Hybrid pump

HyperJet 94i-S or HyperJet 94i-D intensifier pump

Refer to the FlowMaster CD

Refer to manual M-357, Waterveyor Abrasive

Light curtain safety device

Spray containment kit

Flow International Corporation

FlowMaster PC controller includes CAD, path ordering,

Helps when piercing brittle materials such as glass, composite, or stone.

Abrasive flow monitor

Alarm activates when abrasive flow rate exceeds high or

X,Y,Z jog pendant

Flow International Corporation

Mach 3b and Mach 4b Series System

The pumps used with the Mach 3b and Mach 4b Series

Use of recommended oils is vital to proper operation

Ambient temperature 60 to 100F (15.5 to 38C)

Up to 90% @ 100F (38C)

Adequate to operate & service

Use an oil that does not contain anti-wear additives; the

bine Oil GST 46, Exxon Teresstic 46, or Texaco Regal

50i-S: 32 gallons (121 L)

2 microns, continuous flow

Oil-to-water heat exchanger

Optimum oil tem- 105F (40.5C)

HyPlex Hybrid pump

2.5 qt (2.4 liter)

Flow International Corporation

sources of water: cutting and cooling. Also required

pumps each require one water source. Also required

water, and one drain line.

Cooling water (to heat exchanger)

Flow recommends the use of a water softener to

tween 40 and 60 psi (2.8 and 4.1 bar) at all times.

Water flow rate

Flow International Corporation

Mach 3b and Mach 4b Series System

Water interface connections

Intensifier pump utility connections

drain or bucket (can contain oil).