M-127 Small HP Components PDF

SMALL HIGH-PRESSURE
COMPONENTS
M-127 | REV. I | JUNE 2002
Introduction M-127
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.
Instajet™ is a trademark of Flow International Corporation.
© 1985-2001 Flow International Corporation. All rights reserved.
Rev. I — September 2001
2 © Flow International Corporation

M-127 Introduction
Product registration M-127 (Rev. I)

This manual is one of many documents describing Flow International's products. To make future technical
information more useful to you, we would like to hear your comments and suggested
improvements to this manual. Please take the time to complete and return this questionnaire to Flow Inter-
national. Your reply will be carefully reviewed by the Technical Publications Department. Thank you.
Complete and mail to:
Flow International Corporation
Attn: Technical Information & Publications
23500 64th Avenue South
Kent, Washington 98032
Return this form to receive future updates to this manual.
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© Flow International Corporation 3

Introduction M-127
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Company information
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M-127 Introduction
Small High-Pressure Components

Chapter 1. Safety Actuator assemblies
Warnings, cautions, and notes . . . . . . . . . . . . . 9 003840-1 for Instajet II . . . . . . . . . . . . . . . 35
Safety tips . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 C-2741-X normally open, air to close . . . . 36
Protective clothing. . . . . . . . . . . . . . . . . . . . . 12 C-2742-1 normally closed, air to open . . 36
Emergency medical information . . . . . . . . . . 13 Service procedures
On/Off Valve II . . . . . . . . . . . . . . . . . . . . . . 37
Chapter 2. Maintenance & Troubleshooting On/Off Valve I . . . . . . . . . . . . . . . . . . . . . . 40
Using the troubleshooting guide . . . . . . . . . . 15 High-pressure valve . . . . . . . . . . . . . . . . . . 43
Troubleshooting guide . . . . . . . . . . . . . . . . . . 16
Chapter 5. Instajet II Nozzles
Service procedures
Service tips . . . . . . . . . . . . . . . . . . . . . . . . . 18 Operating principles . . . . . . . . . . . . . . . . . . . 46
Using a service log . . . . . . . . . . . . . . . . . . . 18 Instajet II application guidelines . . . . . . . . . . 46
Installing the Instajet II nozzle . . . . . . . . . . . . 47
Chapter 3. Cutting Nozzles
Specifications & parts lists
Installing a cutting nozzle. . . . . . . . . . . . . . . . 19 003850-X Instajet II nozzle assembly . . . . . 48
Specifications and parts lists 003840-1 Instajet II nozzle actuator . . . . . 49
C-1161-1 38-in. nozzle assembly . . . . . . . . 20 003830-X Instajet II nozzle poppet . . . . . . 49
C-2216-X 14-in. nozzle assembly . . . . . . . . 21 Service procedures
C-2455-X 14-in. nozzle assembly . . . . . . . . 22 Servicing the Instajet II nozzle . . . . . . . . . . 50
Service procedures
Replacing nozzle filter screens . . . . . . . . . . 23 Chapter 6. Orifice Mounts & Nozzle Nuts
Installation notes . . . . . . . . . . . . . . . . . . . . . . 53
Chapter 4. On/Off Valves
Product application guidelines . . . . . . . . . . . 25 001821-X Orifice mount assembly . . . . . . 54
Standard on/off valves . . . . . . . . . . . . . . . . . 25 009519-X Orifice mount assembly . . . . . . 54
On/off valve assemblies . . . . . . . . . . . . . . . . . 26 004519-X Orifice mount (standard) . . . . . . 55
Installing on/off valves . . . . . . . . . . . . . . . . . . 26 003788-X Orifice mount (low-mass) . . . . . 55
Specifications and parts lists D-5070-X Diamond orifice mount
Standard on/off valves (Instajet nozzle) . . . . . . . . . . . . . . . . . . . 56
C-2728-1 Normally closed . . . . . . . . . . . 27 D-5071-X Diamond orifice mount
(standard nozzle) . . . . . . . . . . . . . . . . . . . 56
C-2729-X Normally open . . . . . . . . . . . . 28
Nozzle nuts . . . . . . . . . . . . . . . . . . . . . . . . . . 57
012506-1 On/off valve II subassembly. . . . 29
010103-1 On/off valve II . . . . . . . . . . . . . 30 Service procedures
On/off valve & nozzle body assemblies Cleaning orifice assemblies
and nozzle nuts . . . . . . . . . . . . . . . . . . . . . 58
012507-1 with short nozzle . . . . . . . . . . . 31
012508-1 with long nozzle body. . . . . . . . 32 Chapter 7. Swivels
012509-1 with low-mass nozzle nut . . . . . 33
Types of swivels . . . . . . . . . . . . . . . . . . . . . . . 61
012511-1 with 4 nozzle bodies . . . . . . . . 34
Installation notes . . . . . . . . . . . . . . . . . . . . . . 62
Valve assembly
C-2740-1 Valve assembly . . . . . . . . . . . . . 35

Introduction M-127
Specifications & parts lists Non-locking nozzle mountings

010140-1 3 8-in. single axis inline . . . . . . . 63 001327-1 Mounting collar. . . . . . . . . . . . . 99
B-5490-1 ¼-in. single axis inline . . . . . . . . 64 B-2218-1 38-in. Instajet collar. . . . . . . . . . . 99
010142-X 3 8-in. dual axis 90° . . . . . . . . . . 65 B-5078-1 38-in. Instajet collar. . . . . . . . . . 100
B-5725-1 14-in. dual axis 90° . . . . . . . . . . 66 B-6060-1 38-in. Instajet collar. . . . . . . . . . 100
010143-1 3 8-in. single axis 90°. . . . . . . . . . 67 Service procedures
C-5155-1 14-in. single axis 90° . . . . . . . . . . 68 Coning & threading tubing . . . . . . . . . . . . . 101
010141-1 single axis 90° . . . . . . . . . . . . . . 69 Servicing the high-pressure manual valve . . 103
C-5152-1 14-in. parallel axis . . . . . . . . . . . 70
B-5816-1 Bearing assembly . . . . . . . . . . . . 71 Chapter 10. Kits and Tools
Service procedures Nozzle repair kits
B-5490-1 and B-5725-1 . . . . . . . . . . . . . . . 73 007126-X Instajet II nozzle . . . . . . . . . . . 105
010140-1, 010142-X, and 010143-1 . . . . . 75 B-5841-1 Instajet nozzle HP seal . . . . . . 106
010141-X . . . . . . . . . . . . . . . . . . . . . . . . . . 79 On/off valve repair kits
C-5152-1 and C-5155-1 . . . . . . . . . . . . . . 82 001959-1 High-pressure valve . . . . . . . . 106
010200-1 High-pressure valve . . . . . . . . 106
Chapter 8. Filters A-3835 High-pressure manual valve . . 107
Installing inline filters . . . . . . . . . . . . . . . . . . . 85 A-1416 Valve stem . . . . . . . . . . . . . . . 107
B-5741-1 High-pressure valve . . . . . . . . 107
000817-1 38-in. inline filter . . . . . . . . . . . . 86 Poppet repair kits
000905-1 14-in. inline filter . . . . . . . . . . . . 86 B-6280-1 Poppet assembly . . . . . . . . . . . 108
012832-1 38-in. inline filter . . . . . . . . . . . . 87 B-6281-1 Poppet assembly . . . . . . . . . . . 108
Service procedures Swivel repair kits
Replacing the inline filter screen. . . . . . . . . 88 007117-1 38-in. swivel repair kit . . . . . . . 109
B-2281-1 38-in. swivel seal repair kit . . . . 109
Chapter 9. Accessories 007715-1 Inline swivel repair kit . . . . . . . 109
B-5910-1 14-in. swivel repair kit. . . . . . . . 110
High-pressure accessories
B-7447-1 Swivel repair kit . . . . . . . . . . . . 110
Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Tubing shield . . . . . . . . . . . . . . . . . . . . . . . 89 Tools
Tubing clamps . . . . . . . . . . . . . . . . . . . . . . 89 B-5716-1 High-pressure valve tool . . . . . 111
Nipples . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 B-5982-1 High-pressure seal tool . . . . . . 111
Manual valves . . . . . . . . . . . . . . . . . . . . . . 91 007127-1 Poppet removal tool . . . . . . . . 111
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 B-6231-1 Poppet removal tool . . . . . . . . 111
Torque specifications . . . . . . . . . . . . . . . . . 95 C-2690-1 Swivel seal tool . . . . . . . . . . . . 111
C-2691-1 Swivel seal tool . . . . . . . . . . . . 112
Miscellaneous
B-2817-1 3 -in. swivel seal tool . . . . . . . . 112
8
High-pressure gauge . . . . . . . . . . . . . . . . . 95
B-6263-1 Swivel puller . . . . . . . . . . . . . . 112
Maintenance videos . . . . . . . . . . . . . . . . . 95
A-1275 Strap wrench . . . . . . . . . . . . . . 112
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 96
A-6333 Girth wrench . . . . . . . . . . . . . . 112
Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . 96
A-3403 Tool kit. . . . . . . . . . . . . . . . . . . 113
Locking nozzle mountings B-5077-1 Coning & threading kit . . . . . . 113
006144-1 Mounting collar. . . . . . . . . . . . . 97
006967-1 Mounting collar . . . . . . . . . . . . 97
006970-1 Mounting collar . . . . . . . . . . . . 97

M-127 Introduction
Introduction
Small high-pressure components are usually part of a complete waterjet cutting system, which can include
an intensifier pump, a booster pump and filtration system, an operator control station, and a catcher. Your
system may include these or other components. Refer to these component manuals for operating
instructions.
The information in this manual will help you become familiar with your Flow International (FLOW) equip-
ment. This information was compiled from the most current information available at the time of publica-
tion, and is intended to cover the most common configurations. Your equipment was shipped with several
documents, including drawings that include part numbers. Refer to these drawings when using the parts lists
in this and related manuals.
Related documents
This manual is the core manual for all FLOW high-pressure equipment, and is designed to be used with the
following manuals:
• M-287, Model 7X Intensifier Pump
• M-297, PASER® 3 Abrasivejet
• M-310, ESL Intensifier
• M-329, Integrated Flying Bridge with Model 50i-S Intensifier Pump
• M-331, Model 20XW Intensifier Pump
• M-333, Integrated Flying Bridge with Model 100i-D Intensifier Pump
• M-335, Waterjet Machining Center
• M-336, 7X-4140 & 7X-2750 Intensifier Pump
• M-337, 7X-6000 Intensifier Pump
• M-340, 87K Intensifier
• M-353, WMC DWJ
• M-359, PASER® ECL Plus
Flow International Corporation 7

Introduction M-127
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.
Chapter 1 contains a comprehensive list of safety precautions that must be followed to ensure safe opera-
tion 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, and notes

These are specific categories of safety messages, and are defined on the first page of Chapter 1. Everyone
working with or near the equipment must understand the differences between warning, caution, and notes
messages.

CHAPTER 1
Safety
This chapter contains a comprehensive list of safety This label is available from
precautions that must be followed to ensure safe FLOW in two sizes:
operation of the equipment. These precautions • Part # 006317-1
must be read and understood by everyone operat- 3.75 x 6 in.
ing and maintaining the equipment—before they (95 x 152 mm)
start working with the equipment. Note that OSHA • Part # 009837-1
and state safety agency rules must be complied 1.8 x 3 in.
with in addition to those given in this chapter and (46 x 76 mm)
elsewhere in this manual. 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.
FLOW designed your high-pressure waterjet cutting
system and related equipment with safety in mind. Warnings, cautions, and notes
Throughout the manual, safety precautions and Service procedures in the waterjet manuals include
warnings for specific operations are highlighted. safety warnings, cautions, and notes that must be
Safety precautions are also posted on the equip- read, understood, and adhered to. These are spe-
ment. The operator and service personnel shall pay cific categories of safety notices, and are defined as
particular attention to these precautions at all times. follows:
Operators of a high-pressure waterjet cutting sys-
tem must treat the system as they would any WARNING
Highlights an operating condition
high-speed cutting tool. Although the waterjet may or service procedure that can
appear harmless, it is a high-energy cutting tool ca- result in death or serious injury.
pable of cutting many nonmetallic materials such
as composites, plastics, and wood products. CAUTION
Highlights an operating condition or
Misuse of this equipment or carelessness in its ap- service procedure that can lead to impaired
plication can be extremely hazardous to operating system operation or equipment damage.
personnel. Always treat the waterjet cutting system
with respect. Note: Highlights an operating or service
procedure or condition that is considered
essential for efficient operation and service.

Chapter 1. Safety M-127
Safety tips • Be alert at all times when working around the

• Do not allow the waterjet stream to touch any equipment.
part of your body. • Clear all tools, parts, and rags from any moving
• Do not point the waterjet at anyone. parts after servicing the equipment.
• Take the system out of service during mainte- Electrical system
nance. The controls shall be properly locked
and marked with a warning sign. • Only properly trained personnel shall
perform electrical or electronic troubleshooting
• All personnel working on or around the equip-
and servicing.
ment shall pay particular attention to all warn-
ing signs and notices posted in the plant and • Always assume that power is ON in all electrical
on the equipment. systems. Always check and lock out the main
power switches before servicing the equip-
• Protective guards, shields, and covers must be
ment. Post a sign, "Maintenance in Progress—
in place on the equipment at all times.
Do Not Energize."
• First aid facilities shall be provided in conve-
• Live electrical circuits are present in the control
nient locations throughout the plant. These lo-
console whenever the master disconnect is on,
cations must be known by all personnel.
regardless of whether the EMERGENCY STOP is
• The work area around the equipment shall be engaged.
clean and free of debris. Oil spillage results in
• Disconnect circuit breakers and lock them in
slippery floors and must be removed
the OFF position before servicing the electrical
immediately.
system. If this isn't possible, have someone stand
• Any conditions that could result in injury must by to prevent anyone from powering up the
be reported to the plant supervisor without system.
delay.
• Be especially careful when servicing the power
• As a general practice, it is recommended that system in a damp environment.
safety shoes, glasses, and hearing protection be
• Never alter or bypass protective interlocks or
worn by all personnel working around the
devices unless specifically instructed to do so,
equipment. Do not wear rings, watches, or
and only if all precautions are followed.
necklaces when working around any equip-
ment that has moving parts. • Give capacitors enough time to discharge. If
this isn't possible, carefully discharge them
Mechanical system manually.
• Don't start the system unless you know how to • Do not use jumper wires across fuses or fuse
stop it. holders.
• Never maintain, service, or clean around the • Make sure all tools are well insulated.
equipment while it is operating. • Use only proper test apparatus; check it regu-
• Using the wrong tools can result in injury or larly to make sure it works properly.
costly damage to the equipment. • Use caution when connecting a test probe to
• Never climb on or around the equipment on test points.
makeshift devices. Use only approved cat- • All replacement wires shall conform to the
walks, ladders, or platforms. manufacturer’s specifications, including color
• Do not exceed specified pressure settings for coding, wire numbers, and size.
pneumatic or hydraulic components. Ex- • Close the control panel doors or junction box
ceeding these limits can cause serious covers after servicing.
injury to personnel or equipment damage.
• Shield and bundle equipment hoses and cables
so they do not obstruct the operator's freedom
of movement.

M-127 Chapter 1. Safety
Waterjet cutting system High-pressure waterjet cleaning tools

• High-pressure water can remain in the system • Turn off equipment and relieve water pressure
for an extended time after shutting down the before replacing nozzles, tips, or bits.
high-pressure water source. System pressure • Hang a sign on the power supply control panel
can be relieved by opening any valve down- warning that the equipment is being serviced
stream of the outlet valve. and is not available for use until servicing is
• Always bleed down the system pressure complete.
before servicing any part of the system. • Replace all protective covers and shielding on
• Do not touch weep holes with your bare hands equipment before operation.
or try to stop water by plugging the holes. • Check for leakage after nozzle or tip replace-
• The waterjet stream is a knife. Do not put any- ment and correct immediately.
thing in its path that you do not intend to cut. • Use only FLOW manufactured or approved
• Wear a face shield whenever required by the waterjet nozzles, cleaning tips, and drilling or
operating instructions. cutting bits.
• Do not remove protective shields from
high-pressure tubing. If shields are removed
for servicing, they must be replaced before start-
ing the system.
• Torque all fittings to the manufacturer's
specifications.
• Stepping or leaning on high-pressure water
tubing can break connections and cause leaks.
• High-pressure fittings, valves, and tubing must
be certified for 60,000 psi (4140 bar). Do not
make substitutions when altering or adding to
the high-pressure water system. Contact FLOW
Technical Service if you have an 87,000 psi
system.
• Do not alter or eliminate stress relief tubing
coils.
• Follow the tubing manufacturer's recommen-
dations for high-pressure tube bending radii.
• Do not exceed specified operating pressures
for high-pressure components.
• Do not over-torque fittings or bend swivels
excessively.
• Follow the manufacturer's recommendations
for servicing the equipment, and use only origi-
nal manufacturer replacement parts.
• Follow the manufacturer's system startup pro-
cedure to ensure safe operation.
• Use care when lifting equipment covers during
operation.

Protective clothing
Workers operating hand-held, high-pressure water Foot protection
cutting or cleaning equipment and those working
nearby should wear protective clothing and safety • Operators and other person-
devices as described in this chapter. FLOW recom- nel must wear safety foot-
mends that work-site safety personnel approve all wear with steel toe-caps a
minimum of 0.02-in.
safety equipment and clothing for everyone work-
(5 mm) thick. The toe cap
ing around waterjet cutting equipment.
must cover at least 30% of
Eye protection the footwear length.
• The operator's footwear
• At a minimum, operators must have metatarsal guards
must wear safety glasses to provide instep protection.
with side shields and a visor,
or goggles and a visor, to
guard against spray and fly- Body protection
ing debris.
• Waterproof garments only
• All eye protection shall meet
protect the operator from
appropriate ANSI require-
spray and flying debris. They
ments for that type of eye
do NOT deflect direct jet
protection.
impact.
• Some states and countries
have their own eye protec-
tion rules that must be
followed.
Head protection
• Helmets must be worn at all
times by all personnel within
the work area. WARNING
• Helmet material must with- NEVER point a waterjet cutting or
stand mechanical shock to cleaning tool at yourself or at any
person. Do not aim a waterjet tool
10 G in 8 ms without at anything you do not intend to cut.
fracturing.
Hearing protection
• Operators and others ex-
posed to noise levels of
more than 90 dBa for more
than 1 hour must wear suit-
able ear protection. Ear
plugs and muffs are usually
adequate.
Hand protection
• Operator must wear gloves
at all times. Leather gloves
are preferred.

M-127 Chapter 1. Safety
Emergency medical information

Anyone who incurs equipment-related injuries while op-
erating high-pressure water equipment should be given
immediate hospital attention. It is vital that medical per-
sonnel have information about this type of injury. There-
fore, 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 wa-
terjet cutting devices. The tag or card should contain the
information shown in the sample; this card can be pur-
chased from FLOW (P/N A-8466).
Note: this card is applicable to shapecutting and surface
preparation operations only. It is not applicable to pres-
sure vessel applications.
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

55,000 psi (379 MPa, 3793 bar, 3867 kg/cm2) with a jet velocity of
3000 fps (914 mps). This should be taken into account during diagno-
sis. 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 informa-
tion.

Notes

CHAPTER 2
Maintenance & Troubleshooting
Daily inspections and periodic maintenance will Using the troubleshooting guide
help you get the maximum life, safety, and effi- The troubleshooting guide can help you identify the
ciency from your FLOW equipment. Periodic probable cause of a system malfunction and
maintenance includes regularly scheduled preven- establish the most effective corrective action.
tive maintenance, and it also includes replacing
worn parts that have reached the end of their ser- Be sure to also refer to the troubleshooting infor-
vice life. mation in your system manual and any peripheral
equipment manuals when deciding what to
FLOW recommends that you record all service service.
work in a log. Information from this log will help
you decide when to replace parts and schedule • Take a few minutes to listen to the machine
service intervals for system components. These tips and watch it in operation. Learn to recognize
may be helpful: the normal noises and operating conditions of
the system. This will increase your ability to no-
• Stock enough spare parts to minimize down- tice anything unusual.
time and rush part orders.
• Keep careful records of all service performed
• Practice good housekeeping in the work- on the equipment. This informa-
station area. tion will help you stock spare parts and sched-
• Assign a complete set of routinely used ule maintenance.
service tools to the work station.
The most likely causes of each problem are listed

Maintenance schedule in order, starting with the most likely to occur. Each
corrective action is a condensed summary of the
Interval Procedure service required to fix the problem. When you en-
counter a problem, refer to the troubleshooting
Check for loose fittings. guide and:
Check for loose air and water 1. Carefully and precisely define the problem.
connections.
Periodically 2. Locate the symptom that most closely
Ensure flush water is properly resembles the problem.
adjusted and kerf material is not
accumulating inside catcher. 3. Identify the most likely probable cause.
Change nozzle orifice. 4. Follow the corrective action.
As required
Replace or rebuild worn parts. If the symptoms in the guide do not correspond to
Regularly Replace filters. your malfunction, or if the problem is not solved by
the recommended corrective action, contact FLOW
Technical Service.

Chapter 2. Maintenance, Troubleshooting & Service M-127
Troubleshooting guide
1. Waterjet stream does not shut off
Faulty air control valve Check and replace if required.
Debris clogging orifice Service nozzle. Clean orifice assembly as described in the service
assembly procedure in Chapter 6.
Faulty poppet Replace the poppet.
2. Incomplete cutting or poor edge quality
Water pressure is too low • Pump pressure set too low. Increase pressure to recommended
level.
• High-pressure water filters need service. See Chapter 8.
• Leak in high-pressure water system.
• Nozzle needs service. See Chapter 3.
Nozzle is too far from cutting Lower the nozzle closer to the material being cut.
surface
Material feeding too fast, or ori- 1. Reduce material feed rate.
fice is too small for feed rate 2. Change orifice size.
3. Increase water pressure.
Bad orifice assembly Change the orifice assembly.
3. Water splash at catcher and excessive wetting of material
Catcher is full Service the catcher.
Jet misaligned from catcher Realign nozzle and catcher.
Nozzle standoff too high Lower the nozzle.
Excessive spray back Install a vacuum on catcher.
Weep hole leakage Service the nozzle.
Bad orifice assembly Change the orifice assembly.
4. Leakage from nozzle body weep hole

Incorrect torquing of seal housing Re-torque seal housing in accordance with applicable procedures.
to nozzle body
Galled insert Inspect insert and replace if required.
Damaged seal housing Inspect seal housing at insert interface for dents or galling. Replace
if required.
Damaged nozzle body Inspect nozzle body at insert interface for dents or galling. Replace
if required.

M-127 Chapter 2. Maintenance & Troubleshooting
5. Leakage from nozzle

Eroded poppet assembly Service the Instajet nozzle; see Chapter 5.
Debris under poppet
6. Leakage from nozzle nut weep hole
Orifice assembly is not seated Remove nozzle nut and inspect for foreign material preventing
properly proper seating of orifice assembly.
Galled or marred nozzle body 1. Polish nozzle body sealing surface body or replace.
sealing surface and/or orifice as- 2. Replace orifice assembly.
sembly sealing surface
Nozzle nut is not torqued Re-torque nozzle nut to specified torque.
properly.
7. Leakage from seal housing weep hole
Seal assembly failure; seal is ex- Replace seal assembly.
truding around outside diameter
of backup ring.
Seal assembly failure; seal extru- Replace seal assembly.
sion through inside diameter of
backup ring.
8. Nozzle does not actuate
No high-pressure water 1. Open high-pressure water valve.
2. Make sure pump is ON.
3. Check for breaks in lines.
Bleed valve is open Close bleed valve.
System not on Turn intensifier pump on.
Plugged orifice assembly Service orifice and high-pressure water filter. See the Orifice
Cleaning procedure in Chapter 6.
Low or no air pressure 1. Make sure shop air supply is connected and pressure is set to
(on/off valve or Instajet II 70-120 psig (4.8–8.3 bar).
nozzle) 2. Check for breaks in lines.
Wiring or software problems See the electrical and logic diagrams given in the manuals for your
system.
Solenoid is not actuating 1. Make sure there is power to the solenoid (check the LCD on the
solenoid). Service as necessary. Check for broken wires.
2. Make sure the controller is giving a correct signal. Repair as nec-
essary.
9. Leakage at inlet port
Deformed or improperly coned Inspect tubing cone and threads. Recone and rethread as required.
tubing See the High-Pressure Tubing service procedure located in Chapter
9.
Galled cone interface in nozzle Replace the nozzle body.
body

Chapter 2. Maintenance, Troubleshooting & Service M-127
Service procedures
Service procedures are provided for each category Using a service log
of small high-pressure component. Where possible, A periodic maintenance and service log is located
they include illustrations to make service instruc- in the manual for each component. Using a main-
tions easier to understand. These service proce- tenance and service log to record all service work
dures often describe how to replace parts, and also will help you, over time, establish a preventive
may include preventive maintenance instructions. maintenance schedule that is compatible with your
Use the illustrations in each parts list for reference. application and production requirements. Informa-
tion from the log will help you decide when to re-
Service tips place parts and schedule service intervals for
• Inspect the equipment every day before oper- system components. You will find that some com-
ating it. If you see any malfunction, use the ponents have predictable service intervals, and
troubleshooting guide and the applicable ser- others are very dependent on cutting application.
vice procedure to correct the problem.
• Read and thoroughly understand the entire ser-
vice procedure before starting the work. If you
have questions about any part of a procedure,
contact FLOW Technical Service.
• Pay particular attention to the warnings, cau-
tions, and notes in the service procedures.
• If applicable, turn off the electrical power and
relieve the system pressure before performing
any service function. If you must perform a ser-
vice while the equipment is powered, or while
the system is pressurized, take extra precau-
tions to avoid potential injury.
• Handle critical parts with care to avoid scratch-
ing or denting any component.
• Make sure all operating parts of the
machine are clean.
• Remove all parts, tools, and rags from the
equipment before starting it.
• Record all service performed on the equip-
ment. This information will help you plan
when to order spare parts.

CHAPTER 3
Cutting Nozzles
Waterjet cutting nozzles provide a path for the cut- Installing a cutting nozzle
ting water and a way to mount the orifice and noz- Standard waterjet cutting nozzles without integral
zle nut. The nozzles have different orifice sizes and shutoff valves are designed to accept coned and
nozzle nut configurations, and each is designed for threaded stainless steel tubing and are furnished
specific cutting requirements. The nozzles require with a gland and collar. All tubing must be certified
a shut-off valve, which is installed between the for 60,000 psi (4140 bar) water pressure. Contact
nozzle and the high-pressure water source. FLOW Technical Service if you have an 87,000 psi
When ordering a cutting nozzle, the orifice size, (6000 bar) system.
nozzle nut and body length are all important. See Nozzles C-1161-1 and C-2216-X have internal fil-
Chapter 6 for orifice sizes and nozzle nuts for spe- ters that must be changed regularly. Nozzle
cialty applications. C-2455-X does not have an internal filter, so an
Waterjet cutting and performance requirements vary in-line filter must be installed upstream of the noz-
from one application to another, and some compo- zle. For more information on filters, see Chapter 8.
nents are better than others for specific cutting pa- Cutting nozzles are sold without mounts. A typical
rameters. Factors to consider in defining cutting customer-supplied mount is a soft-jaw clamp, simi-
parameters are pump capabilities, water quality, cy- lar to the one shown below.
cles, speed, cut quality, kerf quality, maintenance re-
quirements, and orifice life.
For more information on cutting nozzles or pump
capacity, refer to the applicable pump manual or
The following nozzles are available:
• C-1161-1 for 3 8-in. tubing

• C-2216-X for ¼-in. tubing
• C-2455-X for ¼-in. tubing

Chapter 3. Cutting Nozzles M-127
Specifications and parts lists
C-1161-1 3 -in. nozzle assembly

8
Nozzle bodies available for C-1161-1 Parts list

Body length Nozzle Nozzle 1 A-2838 1 High-pressure gland
Part # "A" length "B" weight
2 A-2839 1 High-pressure collar
in./mm in./mm lb/kg
B-1243-1 4.25/108.0 4.64/117.9 0.68/0.31 3 B-1313-1 1 Filter screen
4 B-1243-1 1 Nozzle body
5 B-1041-1 1 Nozzle nut*
Specifications 6 004519-6 1 Orifice mount assembly*

Max. operating pressure . . . . . . . 60,000 psi (4140 bar) * Other orifice mounts and nozzle nuts are available. See
Chapter 6.
Orifice diameter . . . . . . . . . . . . . . . . . 0.003–0.032 in.
Weight . . . . . . . . . . . . . . . . . . . . . . . . . See table above

M-127 Chapter 3. Cutting Nozzles
C-2216-X 1
4-in. nozzle assembly
Nozzle bodies available for C-2216 Parts list

Body Nozzle Weight 1 A-2866 1 High-pressure gland
-X Part # length "A" length "B"
in./mm in./mm lb/kg
-1 B-5331-1 2.42/61.5 2.81/71.4 0.293/0.13 3 B-5330-1 1 Nozzle nut
-2 B-5331-2 3.42/86.8 3.81/96.8 0.406/0.18
4 B-5331-1 1 Nozzle body (-1 only)
5 B-1313-1 1 Filter screen
6 B-8119-1 1 Insert
Specifications
7 004519-6 1 Orifice mount assembly*
Maximum operating pressure . . 60,000 psi (4140 bar)
8 B-5331-2 1 Nozzle body (-2 only)
Orifice diameter . . . . . . . . . . . . . . . 0.003 to 0.032 in.
Weight . . . . . . . . . . . . . . . . . . . . . . . . . See table above * Additional orifice sizes are available. See Chapter 6.

C-2455-X 1
4 -in. nozzle assembly
Nozzle bodies available for C-2455-X Parts list

Part # Length (in/cm) Weight 1 A-2866 1 High-pressure gland
Assembly Body Body "A" Nozzle "B" lb/kg.
C-2455-1 B-5718-1 2.0/50.8 2.39/60.7 .226/.103 3 B-5330-1 1 Nozzle nut
C-2455-2 B-5718-2 2.5/63.5 2.8973.4 .283/.129
C-2455-3 B-5718-3 3.0/76.2 3.39/86.1 .339/.155 4 B-5718-X 1 Nozzle body (see table)
C-2455-4 B-5718-4 3.5/88.9 3.89/98.8 .396/.180
C-2455-5 B-5718-5 4.0/101.6 4.39/111.5 .452/.206 5 004519-6 1 Orifice mount assembly*
C-2455-6 B-5718-6 4.5114.3 4.89/124.2 .509/.232
* Additional orifice sizes are available. See Chapter 6.
C-2455-7 B-5718-7 5.0/127.0 5.39/136.9 .565/.257
C-2455-8 B-5718-8 6.0/152.4 6.39/162.3 .678/.309
C-2455-9 B-5718-9 7.0/177.8 7.39/187.7 .781/.361
C-2455-10 B-5718-10 8.0/203.2 8.39/213.1 .904/.312
C-2455-11 B-5718-11 9.0228.6 9.39/238.5 1.017/.463
C-2455-12 B-5718-12 10.0/254.0 10.39/263.9 1.130/.515
Specifications
Maximum operating pressure . . . 60,000 psi (4138 bar)
Orifice diameter . . . . . . . . . . . . . . 0.003 to 0.032 inch
Weight . . . . . . . . . . . . . . . . . . . . . . . . . See table above

M-127 Chapter 3. Cutting Nozzles
Replacing nozzle filter screens

This service procedure is for cutting nozzles
C-1161 and C-2216. Before performing this ser-
vice procedure, order a spare filter (B-1313-1).
Note: Replace filter screens on a regular basis.
Whenever you replace the filter screen, FLOW rec-
ommends that you also clean and inspect the ori-
fice assembly.
Service steps
1. Close the water valve that supplies high-
pressure water to the nozzle.
2. Unscrew the high-pressure water gland from
the end of the nozzle assembly. 9. Reinstall the nozzle assembly in the mount
Remove the nozzle. and torque the gland to 35 ft-lb (47 N-m).
3. Place the nozzle nut in a soft-jaw vice. 10. Open the high-pressure water supply
valve and check for leaks. Correct leaks as
4. Untorque, unscrew and remove the required.
nozzle nut assembly from the nozzle body.
Place the nozzle nut in a clean container.
5. Remove the filter screen (B-1313-1) and dis-
card.
Note: Use an easy-out or similar tool if the
screen does not come out easily.
6. Thoroughly clean the nozzle body; air dry.

Note: Clean and inspect the nozzle nut
and orifice assemblies (see procedure in
Chapter 6).
7. Install the new filter screen in the nozzle

body.
8. Install the nozzle nut assembly on the
nozzle body and torque to 35 ft-lb
(48 N-m).
Note: Apply Blue Lubricant (A-2185) to the
nozzle nut threads.

Notes

CHAPTER 4
On/Off Valves
Pneumatically-actuated on/off valves open and Standard on/off valves
close the high-pressure water lines, thus controlling There are three standard on/off valves:
water flow to the cutting nozzles. Two types of
on/off valves are covered in this chapter: • C-2728-1—normally closed, air to open.
• C-2729-1—normally open, air to close.
•Valves that require a separate cutting nozzle.
• 010103-1—a smaller version of the normally
• Valve assemblies, which include the
closed valve. It uses a 38-in. adapter and can re-
cutting nozzle.
place an existing C-2728-1 on/off valve when the
For more information on nozzles, see the flow rate is less than 2 gpm (7.6 lpm).
cutting nozzles chapter of this manual.
Because these valves have perpendicular inlet and
outlet ports, they can be installed in-line in place
Product application guidelines of a high-pressure water elbow fitting. All high-
pressure connections are female ports that accept
Waterjet cutting requirements and performance 3 -in. glands.
8
levels vary from one application to another, and
some components are better than others for spe- Advantages
cific cutting parameters. Look at several factors
when defining cutting parameters—pump capabili- • Easy maintenance.
ties, water quality, cycles, speed, cut quality, kerf • Can go upstream of the cutting nozzle to mini-
quality, maintenance requirements, and orifice life. mize weight at the end effector.
Advantages and disadvantages of the most com-
Disadvantages
monly used on/off valves are listed in this chapter.
• Cyclical operation will fatigue tubing down-
stream of the valve.
• It has a large working envelope.
Application notes
• Ideal for applications with less than 100,000
on/off cycles a year. For more frequent cycles,
an Instajet II nozzle can be more economical.
• Has a life span of 200,000 on/off cycles at
60,000 psi (4140 bar). (This is dependent on
many factors, including water quality and noz-
zle body size.)
• When used downstream of an on/off valve, an
orifice can pop out of its assembly (except when
using diamond orifice D-5071-1).
For more information on orifice mounts, see
Chapter 6.

Chapter 4. On/Off Valves M-127
On/off valve assemblies Installing on/off valves

There are four different on/off valve assemblies; all On/off valves are installed upstream of the nozzle to
include the nozzle body. These assemblies use the control the flow of high-pressure water to the noz-
same actuator assembly; they differ only in nozzle zle. First locate the high-pressure water inlet and
body geometry and the type of orifice and nozzle outlet ports on the valve body. These ports are
nut used. clearly labeled, and are perpendicular to each other
• 012507-1—short nozzle body; uses a so the valve can be installed in-line in place of a
standard nozzle nut. high-pressure water elbow fitting.
• 012508-X—long nozzle body; uses a Both the inlet and outlet ports accept 38-in. outside
standard nozzle nut and Instajet style orifice. diameter coned and threaded stainless steel tubing.
• 012509-1—long, small-diameter nozzle body, The tubing must be certified for 60,000 psi
uses special low-mass nut and orifice assembly. (4140 bar) water pressure. If you have an 87,000
Standard sapphire and diamond orifices cannot psi (6000 bar) system, contact FLOW Technical
be used on this on/off valve. Service.
• 012511-X—can use four different nozzle bod-
ies and a standard nozzle nut. Nozzle body
length depends on cutting application and con-
figuration. Uses a standard orifice.
Maximum flow rate through on/off valve assem-

blies is 2 gpm (7.6 lpm). This is equivalent to a
0.020 inch orifice operated at 60,000 psi
(4140 bar). Higher flow rates are possible, but
component life may suffer.
The valve will create a pressure drop equal to 6 ft.
of 38-in. high-pressure tubing [75 psi (5.2 bar) at
1 gpm (3.8 lpm)].
Advantages
• Easy maintenance.

M-127 Chapter 4. On/Off Valves
Standard on/off valves

C-2728-1 Normally closed
Specifications Parts list

Operating pressure range . . 0–60,000 psi (0–4140 bar) 1 C-2742-1 1 Actuator assembly*
Shop air (dry or ) . . . . . . . . . 50–100 psig (3.5–6.9 bar)
2 C-2740-1 1 Valve assembly*
Typical response time at 60,000 psi water pressure and 3 A-3202 AR Loctite '242' (not shown)
50 psig air pressure:
Opening . . . . . . . . . . . . . . . . . . . . . . . 0.100 second 4 A-0274-6 1 O-ring
Closing. . . . . . . . . . . . . . . . . . . . . . . . . 0.320 second 5 B-5740-1 1 Label
Valve weight . . . . . . . . . . . . . . . . . . . . . . 7 lb (3.17 kg) * A parts list is located in this chapter.
Optional mounting collar. . . . . . . . . . . . . . . B-6060-1*
* Chapter 9 has more information on mounting collars. A

mounting bracket is required to attach the valve and provide
high-pressure plumbing connections.
Repair procedure
• High-pressure valve service procedure is in this
chapter.
• Order repair kit B-5741-1 before beginning
repairs.

C-2729-X Normally open

Operating pressure range . . . . 0–60,000 psi (4140 bar) 1 A-3202 AR Loctite #242 (not shown)
Shop air (dry or ). . . . . . . . 50–100 psig (3.5 to 6.9 bar)
2 C-2740-1 1 HP valve assy*
Typical response time at 60,000 psi water pressure and C-2741-1 1 Actuator assy; NO air (-1 only)
50 psig air pressure: 3
Opening . . . . . . . . . . . . . . . . . . . . . . . 0.100 second C-2741-2 1 Actuator assy; NO oil (-2 only)
Closing. . . . . . . . . . . . . . . . . . . . . . . . . 0.280 second 4 B-5739-1 1 Label
Valve weight . . . . . . . . . . . . . . . . . . . . . . 7 lb (3.17 kg) * A parts lists is located in this chapter.

Note: -1 is air actuated -2 is oil actuated
Optional mounting collar. . . . . . . . . . . . . . . B-6060-1*

Repair procedure
• High-pressure valve service procedure is in this
chapter.
• Order repair kit B-5741-1 before beginning repairs

012506 On/Off Valve II subassembly
Used on on/off valve assemblies 010103, 012507, 012508, 012509, and 102511.

Operating pressure range 1 003840-1 1 Actuator assembly
. . . . . . . . . . . . 22,000–60,000 psi (1517–4140 bar)
2 004096-1 1 Seal retainer
Maximum cycle rate. . . 60 cycles/min (28 hr run time)
Shop air . . . . . . . . . . . . . . . . . . . . . . . must be dry or 3 003845-1 1 Weep tube
Air pressure to open: 4 003831-1 1 Seal

at 22,000 psi water pressure . . . . . . . . . 65 (4.5 bar) 5 003832 1 Backup ring
at 60,000 psi water pressure . . . . . . . . . 45 (3.1 bar)
6 003838-1 1 Bushing
Maximum air pressure . . . . . . . . . . . . . . 120 (8.3 bar)
Maximum flow rate . . . . . . . . . . . . . . . 2 gpm (7.6 lpm) 7 010104-1 1 Valve body
Typical response time at 65 psig air pressure and all 8 010105-1 1 Valve poppet
water pressure and flow rates: 9 006933-1 1 Poppet seat
Opening . . . . . . . . . . . . . . . . . less than 0.10 second
10 A-0275-014 1 O-ring
Closing . . . . . . . . . . . . . . . . . . less than 0.20 second
Valve weight (excluding nozzle) . . . . . 3.40 lb (1.54 kg) 11 B-8075-007 1 O-ring
Optional mounting collar . . . . . . . . . . . . . . 006144-1* 12 A-7002 AR Adhesive
13 A-2185 AR Blue Lubricant (not shown)
14 009971-1 1 Label
Repair procedure
• On/off valve service procedure is in this chapter.
• Order repair kit 010200-1 before beginning
repairs.

010103-1 On/Off Valve II

Operating pressure range 1 001608-1 1 Adapter
. . . . . . . . . . . . 22,000–60,000 psi (1517–4140 bar)
12 A-2838 1 High-pressure gland
Maximum cycle rate. . . 60 cycles/min (28 hr run time)
Shop air . . . . . . . . . . . . . . . . . . . . . . . must be dry or 13 A-2839 1 High-pressure collar
Air pressure to open:
at 22,000 psi water pressure . . . . . . . . . 65 (4.5 bar) 17 012506-1 1 On/off valve II sub-assembly
at 60,000 psi water pressure . . . . . . . . . 45 (3.1 bar) * A parts list for 012506-1 is located in this chapter.
Maximum air pressure . . . . . . . . . . . . . . 120 (8.3 bar)
Maximum flow rate . . . . . . . . . . . . . . . 2 gpm (7.6 lpm)
Typical response time at 65 psig air pressure and all
water pressure and flow rates:
Valve weight (excluding nozzle) . . . . . . 3.4 lb (1.54 kg)
Optional mounting collar . . . . . . . . . . . . . . 006144-1*
Repair procedure
repairs.

On/off valve & nozzle body assemblies

012507-1 With short nozzle

Operating pressure range 1 012506-1 1 On/off valve *
. . . . . . . . . . . . 22,000–60,000 psi (1517–4140 bar)
2 001819-1 1 Nozzle body
Maximum cycle rate . . . . . . . . . . . . . . . . 60 cycles/min
Shop air . . . . . . . . . . . . . . . . . . . must be dry or lubed 3 B-1041-1 1 Nozzle nut
7 001821-6 1 Orifice assembly
at 22,000 psi water pressure . . . . . . 65 psig (4.5 bar) 8 A-2185 1 Blue Lubricant (not shown)
at 60,000 psi water pressure . . . . . . . . . 45 (3.1 bar) * A parts list for 012506-1 is in this chapter.
Maximum air pressure . . . . . . . . . . . 120 psig (8.3 bar) ** Additional orifice sizes are available. See Chapter 6.
Maximum flow rate . . . . . . . . . . . . . . 2 gpm (7.57 lpm)

Typical response time at 65 psig air pressure and all
Valve weight . . . . . . . . . . . . . . . . . . . . 4.25 lb (1.93 kg)

mounting bracket is required to attach the valve and to provide
Repair procedure
repairs.

012508-X with long nozzle body

. . . . . . . . . . . . 22,000–60,000 psi (1517–4140 bar)
2 001995-1 1 Nozzle body (-1 only)
Shop air . . . . . . . . . . . . . . . . . . . must be dry or lubed 3 B-1041-1 1 Nozzle nut
4 001821-6 1 Orifice assembly
at 22,000 psi water pressure . . . . . . 65 psig (4.5 bar) 5 A-2185 AR Blue Lubricant (not shown)
at 60,000 psi water pressure . . . . . . . . . 45 (3.1 bar) 6 001995-2 1 Nozzle body (-2 only)
Maximum air pressure . . . . . . . . . . . 120 psig (8.3 bar) 7 001995-3 1 Nozzle body (-3 only)
8 001995-4 1 Nozzle body (-4 only)
Typical response time at 65 psig air pressure and all 9 002895 1 High-pressure collar (-2 only)
Opening . . . . . . . . . . . . . . . . . Less than 0.10 second 10 A-0792-1 1 Adapter (-2 only)
Closing . . . . . . . . . . . . . . . . . . Less than 0.20 second * A parts list for 012506-1 is located in this chapter.
Valve type . . . . . . . . . . . . . . . . . . . . . . Normally closed
Optional mounting collar . . . . . . . . . . . . . . 006144-1* "A" "B"
in./mm in./mm
* Chapter 9 has more information on mounting collars. A 012508-1 11.63/295 5.36/136
high-pressure plumbing connections. 012508-2 15.41/391 9.14/232
012508-3 13.63/346 7.36/187
Repair procedure 012508-4 12.84/326 6.57/167
• Order high-pressure valve repair kit 010200-1 be-
fore beginning repairs.

012509-1 with low-mass nozzle nut

. . . . . . . . . . . . 22,000–60,000 psi (1517–4140 bar)
2 A-0792-1 1 Adapter
Shop air . . . . . . . . . . . . . . . . . . . must be dry or lubed 3 006144-1 1 Mounting collar
4 006145-1 1 Nozzle body
at 22,000 psi water pressure . . . . . . 65 psig (4.5 bar) 5 006146-1 1 Low-mass nozzle retainer
at 60,000 psi water pressure . . . . . . . . . 45 (3.1 bar) 6 003788-6 1 Low-mass orifice assembly**
Maximum air pressure . . . . . . . . . . . 120 psig (8.3 bar) 7 A-2185 AR Blue Lubricant (not shown)
* A parts list for 012506-1 is located in this chapter.
Typical response time at 65 psig air pressure and all ** Additional orifice sizes are available. See Chapter 6.
Valve type . . . . . . . . . . . . . . . . . . . . . . normally closed
Pressure drop through valve . . . . . . . . 75 psi at 1 gpm
(Equivalent to 6 ft. of 3 8-in. high-pressure tubing)
Repair procedure
• On/off valve service procedure is in this
chapter.
repairs.

012511-X
with 4 available nozzle bodies

. . . . . . . . . . . . 22,000–60,000 psi (1517–4140 bar)
2 B-1041-1 1 Nozzle retainer
Maximum cycle rate . . . . . . . . . . . . . 60 cycles/minute
Shop air . . . . . . . . . . . . . . . . . . . must be dry or lubed 3 004519-5 1 Orifice assembly
at 22,000 psi water pressure . . . . . . 65 psig (4.5 bar) 5 004009-1 1 Nozzle body (012511-1 only)**
at 60,000 psi water pressure . . . . . . . . . 45 (3.1 bar) 6 004009-2 1 Nozzle body (012511-2 only)**
Maximum air pressure . . . . . . . . . . . 120 psig (8.3 bar) 7 004009-3 1 Nozzle body (012511-3 only)**
8 004009-4 1 Nozzle body (012511-4 only)**
Typical response time at 65 psig air pressure and all * A parts list for 012506-1 is located in this chapter.
water pressure and flow rates: ** Order nozzle body in desired length. See drawing for
Opening . . . . . . . . . . . . . . . . . less than 0.10 second dimensions.
"A" "B"
Valve type . . . . . . . . . . . . . . . . . . . . . . normally closed in./mm in./mm
Pressure drop through valve . . . . . . . . 75 psi at 1 gpm
012511-1 12.80/325 6.53/166
(Equivalent to 6 ft. of 3 8-in. high-pressure tubing)
Optional mounting collar . . . . . . . . . . . . . . 006144-1* 012511-2 15.38/391 9.11/231
* Chapter 9 has more information on mounting collars. A 012511-3 11.14/283 4.87/124
high-pressure plumbing connections. 012511-4 13.50/343 7.23/184
Repair procedure
• On/off valve service procedure in this chapter.
repairs.

Valve assembly Actuator assemblies

C-2740-X HP valve assembly 003840-1 for Instajet II
Parts list Parts list
1 B-5975-1 1 Adaptor 1 003835-1 1 Piston rod

2 B-5703-1 1 High-pressure valve seat 2 003843-1 1 Cap assembly
3 B-5702-1 1 High-pressure valve stem 3 A-8472 1 Spring
4 B-5701-1 1 High-pressure seal 4 003841-1 1 Piston
5 B-5723-1 1 Cone seal 5 A-0277-147 1 O-ring
6 B-5700-1 1 Bushing 6 A-0270-300 1 Internal snap ring
7 001822-1 1 High-pressure body 7 003836-1 1 End cap
8 A-0275-008 1 O-ring 8 A-0935-4 1 Connector
9 A-4067 1 Hole plug 9 A-6005 AR Loctite # 262
10 A-4241 1 Oil seal 10 A-4109 AR Tamper-proof glue
11 B-5078-1 1 High-pressure collar (-1 only) 11 004098-1 1 Dust cap
12 A-00167-33 AR Seal
13 A-00167-1 AR U-packing seal
Repair procedure
• See Servicing the high-pressure valve in this
chapter.
• Order repair kit B-5741-1 before beginning
repairs.
Note: Actuator assemblies are not usually field repairable. Parts list is included for information only.

C-2741-1 normally open, air to close

C-2741-2 normally open, oil to close C-2742-1 normally closed, air to open
1 A-4978 1 Compression spring 1 B-8047-1 1 Actuator cap

2 B-5705-1 1 Piston 3 A-4109 AR Tamper-proof glue
3 B-6840-1 1 Actuator shaft 4 A-0275-500 2 Internal snap ring
4 B-5704-1 1 Actuator plate 8 B-5704-1 1 Actuator plate
7 A-0275-013 1 O-ring 9 A-0275-349 1 O-ring
8 A-0275-006 1 O-ring 10 B-5705-1 1 Piston
9 A-4109 AR Tamper-proof glue 11 B-5698-1 1 Actuator shaft
10 A-0275-500 1 Internal snap ring 12 A-0275-248 2 O-ring
16 A-0275-349 1 O-ring 14 C-2448-1 1 Actuator body
19 A-0275-248 1 O-ring 15 A-4066 1 Hole plug
20 C-2448-1 1 Actuator body 16 A-4062 6 Die spring
21 A-4066 1 Hole plug 19 A-0275-013 1 O-ring
23 A-6017 1 Flanged bearing (-1 only) 20 A-6017 1 Bearing
24 B-8047-1 1 Actuator cap 21 A-3202 AR 242
25 A-3202 AR Loctite 242 (not shown) 22 A-0756-2 1 Reducer bushing
26 008230-1 1 Flanged bearing (-2 only) 23 A-0650-3 2 Hex head plug
27 A-0650-3 2 Hex head plug 24 A-14771 1 Breather vent
28 A-0756-2 1 Reducer bushing
29 A-14771 1 Breather vent

On/Off Valve II

Servicing On/Off Valve II

Use this service procedure and the high-pressure
valve repair kit (010200-1) to repair on/off valve
assembly 012506.
Service steps
WARNING
Place the main electrical disconnect in the OFF 9. The poppet seat should now fall
position and bleed down all high-pressure lines. out. If tapping the nozzle body
Place an "Out of Service" tag on the main does not cause the seat to fall out,
electrical disconnect and lock it out. insert a straightened paper clip
into the hole in the seat and
1. Shut down the system. gently loosen the seat. Discard
2. Disconnect the pneumatic control line from the seat.
the valve actuator assembly. 10. Remove the seal retainer from the
3. Remove the orifice assembly from the nozzle opposite end of the valve actuator
body. assembly.
4. Remove the nozzle body.
5. Remove the valve actuator assembly.
6. Loosen the high-pressure water inlet gland
nut to disengage the end of the tubing from
the cone in the high-pressure valve body.
7. Remove the valve actuator assembly from
the mounting collar.
Note: Remove the actuator assembly before
removing the nozzle body if you prefer.
8. Remove the o-ring from the outlet end of the

valve actuator assembly, using a straightened
paper clip or similar tool.
Note: This o-ring is not a seal. It keeps the
poppet seat from falling out when the nozzle 11. Place the wooden dowel (supplied with the
body is removed. repair kit) against the poppet tip and drive
out the poppet stem and high-pressure seal
assembly. Discard the poppet, seal, o-ring,
seal backup ring, and stem bushing.
12. Clean any foreign material from the inside

and outside of the valve body.
13. Lubricate the ultrahigh-pressure o-ring with
White Food Grade O-ring Lube.

14. Place the lubricated o-ring on the seal. 21. Insert the valve assembly into the mounting
15. Install the bushing, seal, and backup ring collar. Carefully align the end of the high-
(seal assembly) onto the stem of the poppet pressure water inlet tubing with the cone in
assembly. Lubricate these components with the high-pressure valve body and torque the
White Food Grade O-ring Lube. gland nut.
Note: You can do this step before Steps 16
and 17 if more convenient.
22. Apply a film of Blue Lubricant to the threads

at the end of the nozzle body.
23. Place the orifice assembly in the nozzle nut.
Make sure the orifice assembly is seated flat
against the bottom of the nozzle nut.
16. Drop the poppet seal assembly into the actu- 24. Install the nozzle nut on the nozzle body.
ator end of the high-pressure valve body, Torque the nozzle nut while holding the noz-
pointed end first. zle body with a wrench to keep it from loos-
ening.
Note: You can do Step 21 before Steps 16
and 17 if more convenient. Note: Nozzle nuts for different on/off valves
require different torques:
17. Use the seal retainer assembly to push the
poppet assembly and the seal package into 001322-1 35–40 ft-lb (47–54 N-m)
their final position. Force the seal retainer 001817-1 30–35 ft-lb (41–47 N-m)
into the body until it bottoms out on the first 002656-1 35–40 ft-lb (47–54 N-m)
step of the nozzle body. 004015-X 35–40 ft-lb (47–54 N-m)
006691-1 12–18 ft-lb (16–24 N-m)
18. Apply Blue Lubricant to the poppet seat, 006920-1 35–40 ft-lb (47–54 N-m)
then insert it into the other end of the
high-pressure valve body. Push the o-ring
into the groove to hold the poppet seat in 25. Attach the pneumatic control line to the valve
place. actuator assembly.
19. Apply Blue Lubricant to the threads at the 26. Turn on the high-pressure water source and
top of the nozzle body and screw it into the slowly raise the pressure while checking for
high-pressure valve body assembly. Torque to leaks. Make sure the valve is operating
35–40 ft-lb (47–54 N-m). correctly.
20. Apply Blue Lubricant to the external threads
of the high-pressure valve body. Screw the
valve body into the valve actuator assembly
and torque to 35–40 ft-lb (47–54 N-m).

On/Off Valve I
Note: This on/off valve is no longer available. Spares are available.

Servicing On/Off Valve I assemblies

Use this service procedure and the High-
Pressure Valve Repair Kit (001959-1) to repair
on/off valve assemblies 001322-1, 001817-1,
002656-1, 004015-X, 006691-1, and 006920-1.
The parts used in this service procedure are shown 10. Remove the retaining cap from
on the drawing on the previous page. the opposite end of the valve ac-
tuator assembly.
Service steps 11. Place the wooden dowel (sup-
plied with the repair kit) against
WARNING the poppet tip and drive out the
Place the main electrical disconnect in the poppet stem and high-pressure
OFF position and bleed down all high-pressure seal assembly.
lines. Place an "Out of Service" tag on the main
electrical disconnect and lock it out. Discard the poppet, seal, o-ring
and seal backup ring.
1. Shut down the system.
2. Disconnect the pneumatic control line from
the valve actuator assembly.
3. Remove the orifice assembly from the
nozzle body.
4. Remove the nozzle body.
5. Remove the valve actuator assembly.
6. Loosen the high-pressure water inlet gland
nut to disengage the end of the tubing from
the cone in the high-pressure valve body.
7. Remove the valve actuator assembly from
the mounting collar. 12. Clean any foreign material from the inside
Note: Remove the actuator assembly before and outside of the valve body.
removing the nozzle body if you prefer. 13. Apply a thin film of White Food Grade O-ring
Lube (A-4689) to the stem of the new pop-
8. Remove the o-ring from the outlet end of the pet, o-ring, high-pressure seal, and seal
valve actuator assembly, using a straightened backup ring.
paper clip or similar tool.
14. Place the o-ring on the high-pressure seal.
Note: This o-ring is not a seal. It keeps
the poppet seat from falling out when the • Push the seal onto the poppet with the
nozzle body is removed. o-ring toward the point of the poppet.
• Push the seal backup ring onto the poppet
stem with the chamfer away from the seal.
The seal assembly should be centered as
much as possible on the poppet stem.
9. The poppet seat should now fall out. If tap-

ping the nozzle body does not cause the seat
to fall out, insert a straightened paper clip
into the hole in the seat and gently loosen
the seat. Discard the seat.

15. Drop the poppet seal assembly into the actu- 18. Apply Blue Lubricant to the threads at the top
ator end of the high-pressure valve body, of the nozzle body and screw it into the
pointed end first. high-pressure valve body assembly. Torque to
Note: You can do Step 20 before Steps 16 35–40 ft-lb (47–54 N-m).
and 17 if more convenient. 19. Apply Blue Lubricant to the external threads
of the high-pressure valve body. Screw the
valve body into the valve actuator assembly
and torque to 35–40 ft-lb (47–54 N-m).
20. Insert the valve assembly into the mounting
collar. Carefully align the end of the high-
pressure water inlet tubing with the cone in
the high-pressure valve body and torque the
gland nut.
Note: You can do this step before Steps 16
and 17 if more convenient.
21. Apply a film of Blue Lubricant to the threads

at the end of the nozzle body.
16. Apply Blue Lubricant (A-2185) to threads of 22. Place the orifice assembly in the nozzle nut.
the retainer cap. Screw in the cap and Make sure the orifice assembly is seated flat
torque to 8–10 ft-lb (11–14 N-m). The re- against the bottom of the
tainer cap will force the seal assembly into nozzle nut.
the bore. 23. Install the nozzle nut on the nozzle body.
Torque the nozzle nut while holding the noz-
zle body with a wrench to keep it from loos-
ening.
Note: Nozzle nuts for different on/off valves
require different torques:
001322-1 35–40 ft-lb (47–54 N-m)
001817-1 30–35 ft-lb (41–47 N-m)
002656-1 35–40 ft-lb (47–54 N-m)
004015-X 35–40 ft-lb (47–54 N-m)
006691-1 12–18 ft-lb (16–24 N-m)
006920-1 35–40 ft-lb (47–54 N-m)
24. Attach the pneumatic control line to the valve

actuator assembly.
17. Apply Blue Lubricant to the poppet seat, 25. Turn on the high-pressure water source and
then insert it into the other end of the high- slowly raise the pressure while checking for
pressure valve body. Push the o-ring into the leaks. Make sure the valve is operating
groove to hold the poppet seat in place. correctly.

High-pressure valve
Use this service procedure to repair on/off valves
C-2728-1, C-2729-1, and C-2740-X. Before begin-
ning this service procedure, order the following.
• B-5741-1 Valve repair kit
• B-5716-1 Valve assembly tool
Service steps 14. Place the seal assembly onto the installation
end of the tool.
WARNING
Place the main electrical disconnect in the 15. Install the seal assembly into the valve body.
OFF position and bleed down all high-pressure
lines. Place an "Out of Service" tag on the main 16. If you removed the oil seal from the actuator
electrical disconnect and lock it out. end of the valve assembly, you must install a
new seal.
1. Shut down the system. Note: This seal is a press fit.
2. Disconnect both high-pressure water lines 17. Install the valve stem in the valve body.
and air lines from the valve assembly.
Note: Make sure the valve stem is flush with
3. Place the valve in a soft-jaw vise and un- the adapter end of the valve body.
screw the actuator assembly from the valve.
18. Install the valve seat in the valve body end
Discard the o-ring on the actuator end of the
first.
valve assembly.
19. Mount the adapter onto the valve body and
CAUTION torque to 35 ft-lb (48 N-m).
Do not disassemble the actuator.
It is not field repairable. 20. Install the new o-ring on the actuator end of
the valve assembly.
4. Reorient the valve in the vise so the adapter 21. Place the valve assembly in a soft-jaw
is up. Unscrew the adapter from the body. vise and install the actuator on the valve as-
5. Remove the valve from the vise and place on sembly. Tighten the actuator until snug.
a clean work table. Note: Apply Loctite #242 (A-3202) to
6. Visually inspect the oil seal on the actuator the threads at the actuator end of the
end of the valve. assembly.
Note: If the oil seal is torn, remove and dis- 22. Remove the assembly from the vise and rein-
card. stall in the high-pressure lines. Torque the
7. Place the seal extraction end of the tool glands to 35–50 ft-lb (48–68 N-m).
against the valve stem. Note: Apply Blue Lubricant (A-2185) to
8. Push on the tool until the seat, stem, o-ring, gland threads.
bushing, and seals come out the other end.
Discard these components. Return the intensifier pump to service. Check for
water leakage.
9. Clean the valve body thoroughly.
10. Place the new bushing on the installation
end of the tool.
11. Install the bushing, chamfered end first, into
the valve body through the adapter end.
12. Install the o-ring and cone seal on the valve
seal as shown.
13. Lubricate all seal assembly surfaces (both ex-
terior and interior) with White Food Grade
O-ring Lube (A-4689).

Notes

CHAPTER 5
Instajet™ II nozzle
The Instajet II nozzle is a pneumatically actuated,
normally closed on/off valve combined with a noz-
zle. (The standard cutting nozzle has a separate
on/off valve.)
The Instajet II nozzle is designed to accept different
orifices and nozzle nuts for specific cutting or
trimming applications. For more information on or-
ifice mount assemblies and nozzle nuts, see
Chapter 6.
The Instajet II nozzle requires shop air pressure to
operate. How long it takes to open or close de-
pends on water pressure, shop air pressure, the
length and diameter of the air line between the air
control valve and the Instajet II nozzle actuator,
and the dynamic characteristics of the air valve
used to apply shop air to the actuator. (Opening
and closing time of the nozzle is defined as the
elapsed time from the signal to open or close, until
the nozzle is fully opened or closed.)
Instajet II nozzles can be controlled by a manu-
ally-operated or solenoid-actuated three-way air
valve.

Chapter 5. Instajet Nozzles M-127
Operating principles Instajet II application guidelines

The Instajet II nozzle has five basic components: Because waterjet cutting requirements and perfor-
actuator, nozzle body, poppet assembly, orifice mance levels vary from one application to another,
mount assembly, and nozzle nut. some components are better than others for spe-
In the static state, the poppet is seated against the cific cutting parameters. Factors to consider in de-
orifice by force from the spring. This spring force fining cutting parameters are pump capabilities,
exceeds the force generated by water pressure at water quality, number of cycles, speed, cut quality,
the inlet port. When shop air is applied, the air kerf quality, maintenance requirements, and orifice
pressure acting on the piston results in an opposing life.
force to the spring force. This offsets the static bal- The Instajet II nozzle has advantages and
ance of forces between the spring and water pres- disadvantages over standard nozzle assemblies.
sure, causing the poppet to open and the
high-energy waterjet stream to emerge. Advantages
As the poppet moves in the nozzle body, the When well-maintained, the Instajet II nozzle has a
high-pressure water flows through the orifice, cre- life span of 750,000 cycles. Its primary advantage
ating a high-energy waterjet. The spring force is ap- is the position of the nozzle relative to the valve.
plied to the poppet by the piston rod. Because there are no components downstream,
High-pressure seals prevent water from leaking to components are not subjected to frequent fatigue
surrounding components and the actuator assem- cycles.
bly. The nozzle nut seals and secures the orifice
mount assembly. The Instajet II nozzle has a weep Disadvantages
tube in the nozzle body to relieve high-pressure
The Instajet II nozzle requires careful maintenance
water if any components fail.
to prevent failure. This nozzle is also more sensitive
to water-borne particulates.
Application notes
In order to achieve 200-millisecond response time,
the pneumatic line to the Instajet II nozzle must be
3 ft (or less) of ¼-in. tubing. If this is not possible, a
quick exhaust valve must be installed.
If you have questions about which Instajet II nozzle
configuration is best suited for your application,

M-127 Chapter 5. Instajet Nozzles
Installing the Instajet II nozzle

Instajet II nozzles require two interface connec- All high-pressure water tubing interface connec-
tions: one for shop air and one for high-pressure tions to the Instajet II nozzle must be fabricated
water. and certified for a minimum working water pres-
The shop air interface connection is designed to sure of 60,000 psi (4140 bar).
accept ¼-in. (6.35 mm) OD plastic air tubing. The The high-pressure water interface connection is a
tubing is installed by sliding the nut and plastic col- coned metal-to-metal seal and must be interfaced
lar onto the plastic tubing, pressing the tubing onto through a mounting block threaded to accept a
the air stem, and screwing on the nut. Other types high-pressure gland. Mounting block details are in
of tubing can be used for the shop air depending Chapter 9; details of the interface connections are
on the severity of the application. When using shown below.
other tubing material, axial load or bending forces
on the shop air interface fitting must not exceed 3 CAUTION
Tubing and inlet port must be properly
lb (13.4 N-m). aligned or equipment will be damaged.


003850-X Instajet II nozzle assembly

Operating pressure range 1 003840-1 1 Actuator assembly **
. . . . . . . . . . . 20,000 to 60,000 psi (1379–4140 bar)
2 004096-1 1 Seal retainer assembly
Orifice diameter
. . . . . . . . . . . . 0.003 to 0.020 in. (0.076-0.508 mm) 3 003845-1 1 Weep tube
Shop air . . . . . . . . . . . . . . . . . . . . . . . . . . . must be dry 4 003832-1 1 Backup ring
Air pressure (at the actuator)
5 003831-1 1 Seal
. . . . . . . . . . . . . . . . . 60 to 120 psig (4.1 to 8.3 bar)
6 B-8075-007 1 Ultrahigh-pressure o-ring
Opening time . . . . . . . . . . . . . . . . . . 100 milliseconds*
Closing time (standard) . . . . . . . . . . . 215 milliseconds* 7 003838-1 1 Stem bushing
Closing time (with quick exhaust) . . . . 125 milliseconds 8 003830-X 1 Poppet assembly†
Ambient operating temperature 9 003828-X 1 Nozzle body
. . . . . . . . . . . . . . . . . . . . maximum 160° F (71.1° C)
10 B-1041-1 1 Nozzle nut*
Nozzle weight . . . . . . . . . . . . . . . . . . . . . 3 lb (1.36 kg)
11 A-7002 AR Adhesive (not shown)
* Figures were obtained with the air solenoid mounted 3 ft
(76.2 mm) from the actuator, fluid pressure of 60,000 psi 12 003846-1 1 Label
(4138 bar), and applied air pressure of 65 psig (4.5 bar). This
does not represent actual cycle time. 13 001821-6 1 Plastic retainer orifice assy *
* See Chapter 6 for additional nozzle nuts and orifice mounts.
Instajet II nozzle assembly ** Only available as an assembly. To order, see "Actuator
assemblies" and "Poppet assemblies" in this chapter.
Assembly Nozzle body Length 'A' Length 'B'
Part # Part # in./mm in./mm
003850-1 003828-1 5.75/146 3.1/78

003850-2 003828-2 5.75/146 4.85/123
003850-3 003828-3 5.75/146 6.56/167
003850-4 003828-4 9.25/235 6.35/161
003850-5 003828-5 11.90/302 3.70/94

003840-1 Nozzle actuator assembly 003830-X Nozzle poppet assembly
Actuator assemblies are not field repairable, and are sold Stem length 'A'
only as assemblies. Poppet Used on this
assembly Instajet II nozzle in./mm
003830-1 003850-1 1.261/32
003830-2 003850-2 3.04/77
003830-3 003850-3 4.75/121
003830-4 003850-4 & -5 8.04/204

Service procedures
Servicing the Instajet II nozzle 6. Move the nozzle to a clean work area.
7. Unscrew the actuator from the nozzle body.
Required parts
8. Remove the nozzle nut and orifice assembly.
• A-2185 Blue Lubricant Inspect for defects; place in a clean
• A-3403-6 Torque wrench location.
• A-4689 White Food Grade O-ring 9. Remove the seal retainer assembly.
Lube
10. Remove the poppet assembly from the noz-
• 007127-1 Poppet removal tool zle body: insert the poppet removal tool into
• 007126-X Poppet assembly repair kit: the body at the orifice end and press on the
-1 for nozzle 003850-1 tool until the seal assembly and poppet as-
-2 for nozzle 003850-2 sembly exit from the actuator end.
-3 for nozzle 003850-3 11. Discard the seal, o-ring, backup ring,
-4 for nozzles 003850-4, -5 bushing, and poppet assembly.
-5 kit without the poppet 12. Clean the orifice assembly, nozzle nut, and
insert. (Use the procedure in Chapter 6.)
CAUTION 13. Check all parts for damage or uneven wear.
During disassembly and reassembly, make sure
the components remain free of contamination. Replace as required.
Work only in a clean, dust-free environment.
14. Lubricate the ultrahigh-

Service steps pressure o-ring with
White Food Grade
WARNING O-ring Lube.
Place the main electrical disconnect in the 15. Position the lubricated
OFF position and bleed down all high-pressure
lines. Place an "Out of Service" tag on the main o-ring on the seal.
electrical disconnect and lock it out.
1. Shut down the system.

16. Install the bushing, seal, and backup ring
2. Remove the air line from the top of the
(seal assembly) onto the stem of the poppet
nozzle.
assembly. Lubricate these components with
3. Un-torque the nozzle nut by holding the White Food Grade O-ring Lube.
nozzle body with one wrench and using an-
other wrench on the nozzle nut. Do not re- CAUTION
move the nozzle nut. Completely remove all protective plastic coating
from the poppet assembly before lubricating.
4. Using two wrenches, remove the inlet
tubing from the nozzle.
• With 38-in. tubing, loosen and remove the
tubing gland nut.
• With ¼-in. tubing, remove the gland nut,
then remove the adapter.
5. Remove the nozzle nut and slide the nozzle
out of the top of the mounting bracket. Im-
mediately replace the nozzle nut to protect
the body tip during transportation.

17. Insert the poppet assembly (with the seal as- 21. Place the nozzle nut onto the nozzle body;
sembly) into the nozzle body at the actuator tighten it finger-tight. This will protect the
end. Continue pushing the assembly until the body tip during transportation.
bushing contacts the first step in the bore.
CAUTION
18. Use the seal retainer assembly to push the Over-torquing the nozzle nut can damage
poppet assembly and seal package into final the orifice assembly and nozzle body.
position. Force the seal retainer into the
body until it bottoms out on the first step of 22. Screw the actuator assembly onto the nozzle
the nozzle body. body. Torque until the actuator bottoms out.
19. Apply Blue Lubricant to nozzle body 23. Remove the nozzle nut. Slip the Instajet II
threads. nozzle back into the mounting collar,
lining up the inlet hole on the Instajet II noz-
20. Place the orifice mount assembly in the noz-
zle with the mounting collar.
zle nut, with the larger mount diameter facing
the nozzle body. CAUTION
Make sure the Instajet II nozzle and
CAUTION mounting collar inlet holes line up, or
Make sure the orifice mount assembly remains the Instajet II nozzle body and the
in place when installing the nozzle nut. high-pressure supply line will be damaged.
24. Reattach the high-pressure water inlet

tubing to the nozzle using a wrench and a
torque wrench.
• With 38-in. tubing, reattach the tubing
gland nut.
• With 14-in. tubing, tighten the adapter to
the collar, and then reattach the tubing
gland nut. Torque the gland nut.

25. With a wrench and a torque wrench (one on

the nozzle body and one on the nozzle nut),
torque the nozzle nut on the nozzle body to
35 ft-lb (47.5 N-m).
26. Reinstall the air line. Turn on air.
27. Turn on the intensifier pump to supply
high-pressure water to the nozzle. You
should see a coherent jet stream.
28. Cycle the nozzle 20 times to test the service
work. Watch for abnormalities. If the nozzle
is not working properly, review this service
procedure and repeat any steps that seem
necessary.

CHAPTER 6
Orifice Mounts & Nozzle Nuts
When the orifice mount is correctly inserted in the Installation notes
nozzle nut, high-pressure water flows through the An upstream screen filter (000905-1 or 000817-1)
nozzle body to the orifice, which creates the is recommended. See Chapter 8 for more
waterjet cutting stream. information.
Not all orifice assemblies are interchangeable. If
you want to know which orifice mount assemblies
will work with your application, see Chapters 3, 4,
and 5, or contact FLOW Technical Service.
Part # Description
001821-X Orifice mount assembly
003788-X Low mass orifice mount assembly
004519-X Orifice mount assembly (standard)
D-5070-X Diamond orifice mount assembly
(Instajet II nozzle)
D-5071-X Diamond orifice mount assembly
(standard)
Notes:
• Orifice assemblies cannot be disassembled,
and they are sold only as an assembly.
• Both sapphire and diamond orifice mount as-
semblies are available
• The diamond orifice is better for production
lines where maximum uptime is critical.

Chapter 6. Orifice Mounts & Nozzle Nuts M-127

001821-X Orifice mount assembly 009519-X Orifice mount assembly
(Instajet)
Available orifice sizes Available orifice sizes

Inside diameter Orifice mount Inside diameter
Orifice mount
part # part # in. mm
in. mm
001821-3 0.003 0.076 009519-7 0.007 0.178
001821-4 0.004 0.102 009519-8 0.008 0.203
001821-5 0.005 0.127 009519-9 0.009 0.229
001821-6 0.006 0.152 009519-10 0.010 0.254
001821-7 0.007 0.178 009519-11 0.011 0.279
001821-8 0.008 0.203 009519-12 0.012 0.305
001821-9 0.009 0.229 009519-13 0.013 0.330

001821-10 0.010 0.254 009519-14 0.014 0.356
001821-11 0.011 0.279 009519-15 0.015 0.381
001821-12 0.012 0.305 009519-16 0.016 0.406
001821-13 0.013 0.330 009519-18 0.018 0.457
001821-14 0.014 0.356 009519-20 0.020 0.508
001821-15 0.015 0.381

001821-16 0.016 0.406 This orifice mount assembly is used on PASER 3 and WMC
001821-17 0.017 0.432 PASER 3 systems. If you are converting from an abrasivejet
001821-18 0.018 0.457 WMC system to a WMC for pure waterjet cutting, order kit
001821-19 0.019 0.483 012990-1.
001821-20 0.020 0.508
001821-21 0.021 0.533

001821-22 0.022 0.558
001821-25 0.025 0.635
001821-26 0.026 0.660
001821-30 0.030 0.762
001821-32 0.032 0.813
This orifice mount assembly is used with on/off valve

001817-1. To find out which orifice mount is best for your
application, contact FLOW Technical Service.

M-127 Chapter 6. Orifice Mounts & Nozzle Nuts
004519-X Orifice mount assembly 003788-X Orifice mount assembly

(standard) (low-mass)
Orifice mount Inside diameter Orifice mount Inside diameter

part # part # in. mm
in. mm
004519-3 0.003 0.076 003788-3 0.003 0.076
004519-4 0.004 0.102 003788-4 0.004 0.102
004519-5 0.005 0.127 003788-5 0.005 0.127
004519-6 0.006 0.152 003788-6 0.006 0.152
004519-7 0.007 0.178 003788-7 0.007 0.178
004519-8 0.008 0.203 003788-8 0.008 0.203
004519-9 0.009 0.229 003788-9 0.009 0.229
004519-10 0.010 0.254 003788-10 0.010 0.254
004519-11 0.011 0.279 003788-11 0.011 0.279
004519-12 0.012 0.305 003788-12 0.012 0.305

004519-13 0.013 0.330 003788-13 0.013 0.330
004519-14 0.014 0.356 003788-14 0.014 0.356
004519-15 0.015 0.381 003788-15 0.015 0.381
004519-16 0.016 0.406 003788-16 0.016 0.406
004519-17 0.017 0.432 003788-17 0.017 0.432
004519-18 0.018 0.457 003788-18 0.018 0.457
004519-19 0.019 0.483 003788-19 0.019 0.483
004519-20 0.020 0.508 003788-20 0.020 0.508
This orifice mount is used on on/off valve 004015-1; cut- This orifice mount is used on on/off valve 006691-1. To
ting nozzles C-1161-1, C-2216-X, and C-2455-X; and is find out which orifice mount is best for your application,
used on the WMC for waterjet-only applications. contact FLOW Technical Service.
To convert a WMC to waterjet cutting (from abrasivejet
cutting), order kit 012990-1.
To find out which orifice mount is best for your applica-
tion, contact FLOW Technical Service.

D-5070-X Diamond orifice mount D-5071-X Diamond orifice mount

assembly (Instajet nozzle) assembly (standard)

Orifice mount Inside diameter Orifice mount Inside diameter
part # in. mm part # in. mm
D-5070-4 0.004 0.102 D-5071-3 0.003 0.076
D-5070-5 0.005 0.127 D-5071-4 0.004 0.102
D-5070-6 0.006 0.152 D-5071-5 0.005 0.127
D-5070-7 0.007 0.178 D-5071-6 0.006 0.152
D-5070-8 0.008 0.203 D-5071-7 0.007 0.178
D-5070-9 0.009 0.229 D-5071-8 0.008 0.203
D-5070-10 0.010 0.254 D-5071-9 0.009 0.229
D-5070-11 0.011 0.279 D-5071-10 0.010 0.254
D-5070-12 0.012 0.305 D-5071-11 0.011 0.279
D-5070-13 0.013 0.330 D-5071-12 0.012 0.305
D-5070-15 0.015 0.381 D-5071-13 0.013 0.330
D-5070-16 0.016 0.407 D-5071-14 0.014 0.356
D-5070-18 0.018 0.457 D-5071-15 0.015 0.381
D-5071-16 0.016 0.407
This orifice mount is used on Instajet II nozzle 003850-X This orifice mount is used on on/off valve 004015-1 (obso-
and on Instajet nozzles C-1770-1, C-1852-1, and lete) and cutting nozzles C-1161-1, C-2216-X, and
C-2475-1. To find out which orifice mount is best for your C-2455-X. To find out which orifice mount is best for your
application, contact FLOW Technical Service. application, contact FLOW Technical Service.
Application notes Application notes

D-5070-X has several advantages over orifice D-5071-X has several advantages over orifice
mount assembly 001821-X: mount assembly 004519-X:
• Orifice D-5070-X has ten times the life of • Orifice D-5071-X has ten times the life of
orifice 001821-X. This reduces frequency of main- orifice 004519-X. This reduces frequency of main-
tenance, thereby delaying, the need for repairs. tenance, thereby delaying, the need for repairs.
• D-5070-X can be cleaned and reused. • D-5071-X can be cleaned and reused.

Nozzle nuts
Nozzle nuts are used on various on/off valves and
cutting nozzles. The nozzle nut part numbers and
possible applications are shown below.
Part # Orifice size Comment
0.127 in.
003786-1 Used on 006691-1
(3.22 mm)
0.127 in.
006146-1 Used on 006691-1
(3.22 mm)
0.15 in.
B-1041-1 Slitting
(3.81 mm)
0.15 in.
B-2861-1 Slitting
(3.81 mm)
0.500 in. (12.7 mm) OD

B-2227-3
trimming
0.15 in. 0.375 in. (9.53 mm) OD
B-2227-2
(3.81 mm) trimming
0.262 in. (6.65 mm) OD
B-2227-1
trimming
0.08 in. 0.143 in. (3.63 mm) OD
B-5029-1
(2.03 mm) trimming
0.15 in.
B-2994-1 Using templates
(3.81 mm)
B-1041-1 and B-2861-1 are the most commonly used

nozzle nuts. To find out which nozzle nut is best for your
application, contact FLOW Technical Service.

Service procedures
Cleaning orifice assemblies
and nozzle nuts 4. Pour 50 ml of each solution into their re-
If you experience degraded waterjet qualities, try spective beakers. Place the beakers into the
cleaning the orifice assembly. This is especially true ultrasonic cleaner tank in the above order,
if your water analysis shows a high level of from left to right.
minerals.
This procedure describes setting up the cleaning
equipment, removing and cleaning the orifice as-
sembly, cleaning the orifice and mount, and reas-
sembling and installing the orifice assembly.
Required equipment
• Ultrasonic cleaner, 70-80 kHz frequency
• Three 100 ml graduated polypropylene
beakers (Fisher Scientific #02-591-10B)
• Two 1-liter bottles with airtight, nonmetallic
caps
• Glacial acetic acid
5. Pour distilled water into the ultrasonic
• Detergent/cleaning agent (Fisher Scientific, cleaner tank until the level is just below the
FL-70 alkaline detergent, #SF105-1) 50 ml mark on the beakers.
• Plastic forceps (Fisher Scientific #10-309) Note: Do not place parts directly into the
• Distilled or de-ionized water ultrasonic cleaner. Placing parts in the beak-
ers allows you to use different cleaning sol-
Mixing cleaning solutions vents in each beaker, speeding up the
1. Pour 720 ml of distilled or de-ionized water cleaning process and using smaller quantities
into a 1-liter bottle. Slowly add 80 ml of gla- of solvents.
cial acetic acid to make a 10% solution. Cap
the bottle and swirl to mix. Label and date
the container.
2. Pour 440 ml of distilled or de-ionized water
into a 1-liter bottle. Slowly add 440 ml of
the FL-70 detergent to make a 50% solution.
Cap the bottle, swirl to mix, then label and
date it.
3. Label the three beakers as follows:
• 10% acetic acid
• 50% distilled water
• Distilled water

Removing the orifice assembly
WARNING
Before disassembling the nozzle or nozzle
assembly, depressurize the high-pressure
supply line and deactivate the shop air
supply and any electrical connection that
can restore high-pressure water to the line.
1. Using two wrenches, loosen and remove the

nozzle nut from the nozzle.
2. Remove the orifice assembly from the nozzle
nut. If not cleaning immediately, separate by
orifice size and place in distilled water in la- 3. Inspect each orifice assembly to make sure
beled, sealed containers. This will prevent the ultrasonic cleaning has not dislodged the
deposits from drying out, making them easier orifice. After air drying, store the assemblies
to clean. in clean containers marked with the orifice
size.
Cleaning process 4. Repeat the above cleaning process to clean
1. Set up three beakers and ultrasonic cleaner as the nozzle nuts.
described in Mixing cleaning solutions.
2. Turn on the ultrasonic cleaner.
Orifice assemblies will be cycled through the
three beakers and different solutions, as de-
scribed in Cleaning the orifice assembly. AL-
WAYS handle the orifice assemblies with
forceps.
a. Put a maximum of 4 orifice assemblies in
the first beaker (acetic acid). Let them
soak five minutes, then move them to
the second beaker (detergent).
b. Place 4 more orifice assemblies in the
first (acetic acid) beaker.
c. Wait 5 minutes, then move the orifice
assemblies one beaker to the right (move
the orifices in the detergent to the dis-
tilled water; orifices in the acetic acid to
the detergent). Place more orifice assem-
blies into the acetic acid.
d. After 5 minutes take the assemblies out
of the distilled water beaker to a clean,
lint-free towel. Let them air dry.
e. Continue the cleaning process for the re-
maining orifice assemblies.

Notes

CHAPTER 7
Swivels
Swivels are rotary joints used upstream of the cut- Single axis 90° swivels
ting nozzle. They allow relative movement be- (010143-X and C-5155-1)
tween high-pressure plumbing components, and 010143-1 for 60K, -2 for 40K
they transfer water from a fixed location to a rotat-
• C-5155-1 — applications with a right angle,
ing member or between two rotating members. 1 -in. tubing connection and rotation around a
4
single axis. It has two female coned and
Types of swivels threaded high-pressure connections.
Description 3 -in. 1 -in. • 010143-X — applications with a right angle,
8 4
3 -in. tubing connection and rotation around a
8
Single axis, inline 010140-X B-5490-1 single axis. It has two coned and threaded
Dual axis, 90° 010142-X B-5725-1 high-pressure connections (one male and one
female).
Single axis, 90° 010143-X C-5155-1
• Mounted in-line. If properly aligned, can be
Parallel axis — C-5152-1
rigidly supported. See installation notes.
Single axis, 90°, bearing mount 010141-X —
Parallel axis swivel

(C-5152-1)
Single axis inline swivels
(010140-X and B-5490-1) • For applications where a straight ¼-in. tubing
run must bend, such as at a pin joint in a
010140-1 for 60K, -2 for 40K linkage.
• For applications that require rotation around a • Two female coned and threaded high-
single axis. Connect to ¼-in. or 38-in. tubing. pressure connections.
• One female and one male coned and threaded • Mounted in-line.
high-pressure connection.
• Mounted in-line or rigidly supported. Bearing-mounted, single axis 90° swivel
(010141-X)
Dual axis 90° swivels 010141-1 for 60K, -2 for 40K
(010142-X and B-5725-1)
• For applications that require right-angle,
010142-1 for 60K, -2 for 40K 3
8-in. tubing connections with rotation
• For applications where 90° tubing connections around a single axis.
are needed in conjunction with two independ- • One male and one female high-pressure
ent axes of rotation. Connect to ¼-in. or 38-in. connection.
tubing. • Not for line mounting. When properly aligned,
• Two male coned and threaded high-pressure the external bearing can reduce stress on inter-
connections. nal components, extending swivel life under
• Mounted in-line; if properly aligned, can be heavy radial loads.
rigidly supported.

Chapter 7. Swivels M-127
Installation notes
In line-mounted installations, tubing supports will
provide some rigidity and cause the least bending
and axial loads. Maximum bending and axial loads
defined for each swivel must not be exceeded. The
swivels come with glands and collars for female
high-pressure tubing and/or union connections, and
male interface connections come with a coned and
threaded nipple.
Gland torque specifications

Torque
Fitting size
ft-lb N-m
¼ in. 10-15 14-20
3 in. 40-50 20-27
8
16 in. 60-75 81-102
9
Note: Always lubricate threads and the area be-

tween the gland nuts and collars with Blue Lubri-
cant (A-2185).

M-127 Chapter 7. Swivels

010140-X 3 -in. single axis in-line
8

Operating pressure (max.): 1 A-2839 2 High-pressure collar
010140-1 . . . . . . . . . . . . . . . . 60,000 psi (4140 bar)
010140-2 . . . . . . . . . . . . . . . . 40,000 psi (2750 bar) 2 A-0689-2 2 Gland collet
3 B-1791-2 1 Swivel seal
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 360° optional
Rotation speed (max.) . . . . . . . . . . . . . . . . . . . 250 rpm 4 B-8075-009 1 Ultrahigh-pressure o-ring
Pressure drop: 5 B-1790-1 1 Swivel seal ring
. . . equivalent to 11 ft (3.4 m) of 3 8-in. OD HP tubing
6 B-1789-1 1 Backup ring seal
Flow direction. . . . . . . . . . . . . . . . . . . . . . . . . Optional
7 B-1788-1 1 Swivel thrust plug
Operating torque (max.)
8 A-0275-017 1 O-ring
Running . . . . . . . . . . . . . . . . . . . . 16 in-lb (1.8 N-m)
Starting . . . . . . . . . . . . . . . . . . . . . 20 in-lb (2.3 N-m) 11 A-8516 1 Needle ball bearing
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 lb (0.54 kg) 15 010133-1 1 Housing
Operating axial bending load (max.) 16 A-2007 1 Oil seal
. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in-lb (3.4 N-m) 17 A-8559 AR Grease (not shown)
Operating axial load (max.)
18 007116-1 1 Shaft assembly (-1 only)
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (111 N)
Compressive () . . . . . . . . . . . . . . . . . . . . . . 2 lb (9 N) 19 010139-1 1 Thrust/seal collar
Compressive (30,000 psi min.). . . . . 600 lb (2700 N) 20 007116-2 1 Shaft assembly (-2 only)
Operating temperature range . . . . . 47–110°F (8–43°C)
010140-1 for 60,000 psi
010140-2 for 40,000 psi
Repair procedure
• Service procedure is in this chapter.
• Order repair kit 007117-1 and tool B-2817-1. See
Chapter 10.

B-5490-1 1 -in. single axis in-line

4

Operating pressure (max.) . . . . . 60,000 psi (4140 bar) 1 C-5500-1 1 Swivel housing
2 A-4411 AR Waterproof grease
Rotation speed (max.) . . . . . . . . . . . . . . . . . . . 250 rpm
3 B-6659-1 1 Thrust nut
Pressure drop:
. . . . equivalent to 3.3 ft (1 m) of 14-in. OD HP tubing 4 A-2866 2 High-pressure gland
Flow direction. . . . . . . . . . . . . . . . . . . . . . . . . Optional 5 A-3823 2 Bearing race
Operating torque (max.) 6 A-3822 1 Bearing

Running . . . . . . . . . . . . . . . . . . . . 10 in-lb (1.1 N-m) 7 A-2867 2 High-pressure collar
Starting . . . . . . . . . . . . . . . . . . . . . 14 in-lb (1.6 N-m) 9 B-1790-1 1 Seal ring
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 0.4 lb (0.18 kg) 11 A-0275-007 1 O-ring
Operating axial bending load (max.) 12 B-5495-1 1 Bearing housing
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in-lb (1.7 N-m)
13 B-5492-1 1 Backup ring
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (111 N)
Compressive (unpressurized) . . . . . . . . . . . 2 lb (9 N) 15 B-5491-1 1 Swivel shaft
Compressive (30,000 psi min.). . . . . 600 lb (2670 N) 16 B-8075-009 1 Ultrahigh-pressure o-ring
Repair procedure
• Service procedure is located in this chapter.
• Order repair kit B-5910-1 and tools B-6263-1 and
C-2691-1. See Chapter 10.

010142-X 3 -in. dual axis 90°

8

010142-1 . . . . . . . . . . . . . . . . 60,000 psi (4140 bar)
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . 360° optional 3 B-1791-2 2 Swivel seal
Rotation speed (maximum) . . . . . . . . . . . . . . . 250 rpm 4 B-8075-009 2 Ultrahigh-pressure o-ring
Pressure drop:
. . . equivalent to 22 ft (6.8 m) of 3 8-in. OD HP tubing 5 B-1790-1 2 Swivel seal ring
Flow direction. . . . . . . . . . . . . . . . . . . . . . . . . Optional 6 B-1789-1 2 Backup ring seal
Operating torque (max.) 7 B-1788-1 2 Swivel thrust plug

Running . . . . . . . . . . . . . . . . . . . . 16 in-lb (1.8 N-m) 8 A-0275-017 2 O-ring
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 lb (1.04 kg)
15 A-2007 2 Oil seal
Operating axial bending load (max.) 16 010136-1 1 90° dual swivel housing
. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 in-lb (3.4 N-m)
Operating axial load (max.) 17 A-8559 AR Grease (not shown)
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (111 N) 18 007116-1 2 Shaft assembly, -1 only
Compressive () . . . . . . . . . . . . . . . . . . . . . . 2 lb (9 N) 19 010139-1 2 Thrust/seal collar
Compressive (30,000 psi min.). . . . . 600 lb (2670 N)
20 007116-2 2 Shaft assembly, -2 only
010142-1 for 60,000 psi

Repair procedure
010142-2 for 40,000 psi
Chapter 10.

B-5725-1 1 -in. dual axis 90°

4

Operating pressure (max.) . . . . . 60,000 psi (4140 bar) 1 A-4411 AR Waterproof grease
Pressure drop: 3 A-2867-1 2 High-pressure collar
. . . . equivalent to 6.6 ft (2 m) of 14-in. OD HP tubing 4 B-1790-1 2 Seal ring
6 A-0275-007 2 O-ring
Operating torque (max.): 7 B-5495-1 2 Bearing housing
Running . . . . . . . . . . . . . . . . . . . . 10 in-lb (1.1 N-m)
Starting . . . . . . . . . . . . . . . . . . . . . 14 in-lb (1.6 N-m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 0.7 lb (0.32 kg)
10 B-5491-1 2 Swivel shaft
Operating axial bending load (max.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in-lb (1.7 N-m) 11 B-8075-009 2 Ultrahigh-pressure o-ring
Operating axial load (max.) 12 A-2866 2 High-pressure gland
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (111 N) 13 B-5724-1 1 Swivel housing
Compressive (unpressurized) . . . . . . . . . . . 2 lb (9 N)
14 A-3823 4 Bearing race
15 A-3822 2 Bearing
Repair procedure
• Order repair kit B-5910-1 and tools B-6263-1 and
C-2691-1. See Chapter 10.

010143-X 3 -in. single axis 90°

8

010143-1 . . . . . . . . . . . . . . . . 60,000 psi (4140 bar)
Rotation speed (maximum) . . . . . . . . . . . . . . . 250 rpm 4 B-8075-009 1 O-ring
Pressure drop:
5 B-1790-1 1 Swivel seal ring
. . . equivalent to 11 ft (3.3 m) of 3 8-in. OD HP tubing
7 B-1788-1 1 Swivel thrust plug
Operating torque (max.)
Running . . . . . . . . . . . . . . . . . . . . 16 in-lb (1.8 N-m) 8 A-0275-017 1 O-ring
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 lb (0.86 kg) 15 010138-1 1 90° swivel housing
Operating axial bending load . . . . . . 30 in-lb (3.4 N-m) 16 A-2007 1 Oil seal
Operating axial load (max.): 17 A-8559 AR Grease (not shown)
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (111 N) 18 007116-1 1 Shaft assembly (-1 only)
Compressive () . . . . . . . . . . . . . . . . . . . . . . 2 lb (9 N)
19 010139-1 1 Thrust/seal collar
Operating temperature range . . . . . 47–110°F (8–43°C) 20 007116-2 1 Shaft assembly (-2 only)
010143-1 for 60,000 psi

Repair procedure 010143-2 for 40,000 psi
Chapter 10.

C-5155-1 1 -in. single axis 90°

4

Operating pressure (max.) . . . . . 60,000 psi (4140 bar) 1 C-5151-1 1 Collar
2 B-7159-1 1 Swivel shaft
Rotation speed (maximum) . . . . . . . . . . . . . . . 250 rpm
Pressure drop: 3 B-7163-1 1 Spacer
. . . . . equivalent to 3.3 ft (1 m) of 14-in. OD HP tubing 4 B-7160-1 1 Thrust nut
Flow direction. . . . . . . . . . . . . . . . . . . . . . . . . Optional 5 D-2443-1 1 Swivel housing
Operating torque (max.) 6 B-5694-1 2 Backup ring
Running . . . . . . . . . . . . . . . . . . . . 20 in-lb (2.3 N-m) 7 B-8075-009 2 Ultrahigh-pressure o-ring
Starting . . . . . . . . . . . . . . . . . . . . . 24 in-lb (2.7 N-m)
8 A-2866 2 High-pressure gland
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 lb (0.36 kg) 9 A-2867 2 High-pressure collar
Operating axial bending load (max.) 10 B-1791-2 2 Swivel seal
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in-lb (1.7 N-m)
11 B-1790-1 2 Seal ring
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 lb (8.9 N)
Compressive (unpressurized) . . . . . . . . . 20 lb (89 N)
Repair procedure
• Order repair kit B-7447-1 and tool C-2690-1. See
Chapter 10.

010141-X Single axis, 90° bearing mounted

010141-1 . . . . . . . . . . . . . . . . 60,000 psi (4140 bar)
010141-2 . . . . . . . . . . . . . . . 40,000 psi (2750 bar) 2 A-0689-2 2 Gland collet
Rotation speed (maximum) . . . . . . . . . . . . . . . 250 rpm 4 B-8075-009 1 O-ring
Pressure drop:
. . . . equivalent to 11 ft (3.3 m) of 3 8-in. OD HP tubing 5 B-1790-1 1 Swivel seal ring
Operating torque (max.) 7 B-1788-1 1 Swivel thrust plug
Running . . . . . . . . . . . . . . . . . . . . . 20 in-lb 2.3 N-m)
8 A-0275-017 1 O-ring
Starting . . . . . . . . . . . . . . . . . . . . . 24 in-lb (2.7 N-m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 lb (1 kg) 11 A-8516 1 Needle ball bearing
Operating axial bending load . . . . . . 15 in-lb (1.7 N-m) 15 010137-1 1 90° swivel housing
Operating axial load (max.): 16 A-2007 1 Oil seal
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . 25 lb (111 N)
17 A-8559 AR Grease (not shown)
Compressive () . . . . . . . . . . . . . . . . . . . . . . 2 lb (9 N)
18 B-8557-1 1 Modified E-ring
Operating temperature range . . . . . 47–110°F (8–43°C) 19 A-4121 1 Inner race
Application notes 21 010139-1 1 Thrust/seal collar
• This swivel is used with bearing assembly
B-5816-1.
010141-1 for 60,000 psi

Repair procedure 010141-2 for 40,000 psi
• Order repair kit 007117-1 and tool B-2817-1.
See Chapter 10.

C-5152-1 1 -in. parallel axis

4

Operating pressure (max.) . . . . . 60,000 psi (4140 bar) 1 C-5150-1 1 Collar
2 B-7163-1 1 Spacer
Pressure drop: 3 B-7158-1 1 Swivel shaft *
. . . . . equivalent to 3.3 ft (1 m) of 14-in. OD HP tubing 4 B-7160-1 1 Thrust nut
5 D-2443-1 1 Swivel housing
Operating torque (max.) 6 B-5731-1 1 Plug *
Running . . . . . . . . . . . . . . . . . . . . 20 in-lb (2.3 N-m)
Starting . . . . . . . . . . . . . . . . . . . . . 24 in-lb (2.7 N-m)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 lb (0.36 kg) 8 A-0515-3 1 Set screw *
Operating axial bending load (max.)
. . . . . . . . . . . . . . . . . . . . . . . . . . . 15 in-lb (1.7 N-m) 10 A-2866 2 High-pressure gland
Operating axial load (max.) 11 A-2867 2 High-pressure collar
Tensile . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 lb (8.9 N)
12 B-1791-2 2 Seal ring
Compressive (unpressurized) . . . . . . . . . 20 lb (89 N)
14 A-3202 AR Loctite "242" (not shown)
Repair procedure
• Service procedure is located in this chapter. * Note: Order swivel shaft kit 014002-1 to get these three
• Order repair kit 007447-1 and tool B-2817-1. See parts. You cannot order them separately.
Chapter 10.

B-5816-1 Bearing assembly
Application notes Parts list

This bearing assembly is used with bearing-mounted 1 B-5793-1 1 Bearing mounting block
swivels C-2515-1 and 010141-1.
2 A-4156 1 Roller bearing
3 A-0275-218 1 Snap ring

Service procedures
B-5490-1 and B-5725-1
The internal design of these swivels is identical. Use this service procedure when repairing
either swivel; just repeat the procedure for the second side of the dual axis swivel (B-5725-1).
Single axis inline swivel (B-5490-1)
Dual axis 90° swivel (B-5725-1)

Required kits and tools 11. Remove the o-ring from the bearing housing.
Discard.
• B-5910-1 14-in. swivel repair kit
• B-6263-1 Swivel puller tool 12. Thoroughly clean the swivel housing, bearing
• C-2691-1 Seal installation and removal tool housing, swivel shaft, and thrust nut using a
mild cleaning solvent. Blow dry.
For more information on these parts, see 13. Inspect all sealing surfaces for galling or heavy
Chapter 10. wear. Replace components as required.
Disassembly Assembly
1. Remove all replacement parts from the
WARNING swivel seal repair kit (B-5910-1).
Place the main electrical disconnect in the off po-
sition. Bleed down all high-pressure lines. Lock 2. Install the new ultrahigh-pressure o-ring on
out the main electrical disconnect and display an the minor diameter of the swivel seal as
"Out of Service" tag. Failure to do so may result in
equipment damage or injury to personnel. shown.
1. Turn off the power to the equipment.

2. Bleed the high-pressure water from the
system.
CAUTION
This service work must be conducted
in a clean environment to avoid 3. Install the seal ring on the tapered portion of
contaminating system components. the swivel seal.
Note: The seal ring also has a tapered por-
3. Unscrew the high-pressure glands that con-
tion. Make sure the thin side of the seal ring
nect the high-pressure water lines to the
is installed first.
swivel.
4. Unscrew the high-pressure collar from the
swivel shaft; remove the high-pressure gland.
5. Unscrew the thrust nut from the swivel
housing.
Note: Inspect the swivel shaft for burrs.
Deburr before removing the thrust nut. 4. Thoroughly lubricate the seal assembly and
backup ring. With the ultrahigh-pressure
6. Slide the thrust nut from the swivel shaft and o-ring entering first, insert into the seal cav-
store in a clean container. ity, using the end of the installation tool
7. Pull the swivel shaft from the housing. (C-2691-1). Gently rotate the installation
Note: Swivel shaft, bearing races and bear- tool when removing it.
ing housing will exit as a unit. Note: A correctly installed backup ring will be
flush with the seal cavity edge.
8. Remove and discard the bearing and both
bearing races. Store the swivel shaft and 5. Install the o-ring into the bearing housing.
bearing housing in a clean container.
9. Insert the swivel seal puller tool into the seal
cavity, engaging the seal components.
10. Remove the backup ring and the seal assem-
bly (seal ring, swivel seal, and ultrahigh-
pressure o-ring) from the seal cavity.
Discard.

6. Pack the bearing housing about one-half full WARNING

with light molybdenum-based grease, such Be careful when pressurizing any new,
as Dow Corning BR 2 Plus. Install the bear- rebuilt, or serviced high-pressure system or
ing housing into the swivel housing with the component. Increase pressure slowly [20,000 psi
(1379 bar) per minute maximum]. Apply system
greased cavity (and o-ring) facing outward. pressure for at least three minutes, and cycle
Note: Lubricate the minor diameter of the pressure on and off at least three times.
swivel shaft and the o-ring. Lubricate the
bearing and bearing races with a molybde- 13. Pressurize the system.
num-based grease. 14. Check for leakage.
7. Place one bearing race onto the larger diam- CAUTION

eter of the swivel shaft. Then add the bear- Continuous seal leakage can permanently
damage the swivel housing or swivel shaft.
ing and the other bearing race. Recheck for proper seal installation.
If tube fittings leak, remove the tube and rework

the conical surface as described in High-pressure
tubing coning and threading in Chapter 9.
Do not over-torque fittings to stop leakage.
The service procedure is complete.
8. Lubricate both ends of the swivel shaft with

molybdenum-based grease and insert, minor
diameter first, into the swivel housing.
9. Apply Blue Lubricant (A-2185) to the threads
of the thrust nut, and screw the thrust nut
into the swivel housing. Torque to 50 ft-lb
(68 N-m).
10. Apply Blue Lubricant to the high-pressure
gland threads, and then reinstall the high-
pressure gland and high-pressure collar on
the swivel shaft.
11. Torque both high-pressure glands to
15–25 ft-lb (21–34 N-m).
12. Determine the swivel's final angle of place-
ment, then install it. Tighten all other fittings
around the swivel. This is done to minimize
torsional stress on the swivel.

010140-1, 010142-X, and 010143-1

Use this procedure to repair any of these swivels. When servicing the dual axis swivel, repeat the
procedure for the other side.
Single axis inline swivel (010140-1)
90° dual-axis swivel (010142-X)

90° single axis swivel (010143-1)
Required kits and tools 9. Unscrew the thrust plug and remove.
For more information on these parts, see 10. Carefully remove the backup ring, seal ring,
Chapter 10. swivel seal and ultrahigh-pressure o-ring
from the seal cavity; discard.
• 007117-1 3
8-in. swivel seal repair kit
B-2817-1 Note: Use the swivel seal tool and loosen
8-in. swivel seal tool
• 3
the set screw that holds the center pin in the
Disassembly tool. Replace the center pin with a #10 tap.
The tap inserted in the ID of the rings will
WARNING make them easier to remove.
Place the main electrical disconnect in the off
position. Bleed down all high-pressure lines. Lock 11. Remove the needle ball bearing and
out the main electrical disconnect and display an thrust/seal collar from the swivel shaft assem-
equipment damage or injury to personnel. bly and discard.
12. Clean the swivel housing and swivel shaft
1. Turn off power to the equipment. thoroughly using mild cleaning solvent. Blow
2. Bleed the high-pressure water from the dry.
system. 13. Inspect all sealing surfaces and areas of bear-
ing contact for galling or heavy wear. Re-
CAUTION place components as required.
Service must be conducted in a clean environment
to avoid contaminating system components. 14. Inspect the needle ball bearing for damage.
Inspect the inner ring of the swivel shaft. If it
3. Unscrew the gland collet that connects the has scores or gouges, the bearing must be re-
high-pressure water supply line to the swivel. placed. Rotate the bearing to feel if any
4. Unscrew the gland collet from the high- damage to the needle bearing (radial loads)
pressure plumbing. or ball bearings (thrust loads) is apparent.
5. Unscrew the high-pressure collar from the • If the bearing does not rotate smoothly, it
swivel shaft and remove the gland collet. must be replaced.
6. Unscrew the thrust/seal collar. • If the bearing is good, re-pack it with grease
and use it again.
7. Pull the swivel shaft and needle ball
bearing from the swivel housing. Note: FLOW recommends that you replace
the shaft assembly (007116-1) and oil seal
8. Insert the swivel seal tool into the thrust
each time you replace the swivel seal, seal
plug, engaging the two dowel pins in the
ring, and backup ring. Replace the needle
thrust plug ports.
ball as needed.

Assembly
swivel seal repair kit (007117-1).
2. Install the ultrahigh-pressure o-ring onto the
minor diameter of the swivel seal.
3. Install the seal ring onto the tapered portion
of the swivel seal.
6. Apply Blue Lubricant (A-2185) to the thrust

plug and install it in the swivel housing using
the seal installation tool.
7. Install o-ring on the swivel shaft assembly.
Note: Lubricate the minor diameter of the
4. Install the seal assembly and backup ring into swivel shaft and the o-ring with White Food
the seal cavity with the ultrahigh-pressure Grade O-ring Lube.
o-ring entering first as shown. 8. Lubricate the bearing thoroughly with
To make installation easier, stack the assembly lithium-based MP grease (or equivalent).
on the center pin of the swivel seal tool. Add
a small amount of white food grade o-ring
lube (A-4689) to keep the parts from falling
off the center pin. Be sure that the assembly
is oriented correctly, with the ultrahigh-pres-
sure o-ring entering first as shown.
9. Install the new oil seal into the thrust/seal

collar. Orient the oil seal with the lip out, as
shown above.
10. Press the thrust/seal collar onto the needle
ball bearing as shown.
5. Install the seal backup ring in the seal
cavity.
Note: The backup ring must be flush with
the seal cavity edge.
11. Install the needle ball bearing and thrust/seal

collar onto the shaft assembly.
12. Insert the swivel shaft into the thrust plug,
with the needle ball bearing and the minor
diameter of the thrust/seal collar entering
first. Screw the collar into place.

13. Reinstall the gland collet and high-pressure

collar on the swivel shaft.
14. Determine the swivel's final angle of place-
ment, then install it. Tighten all other fittings
around the swivel. This is done to minimize
torsional stress on the swivel.
15. Tighten the gland collet attached to the
swivel shaft into the high-pressure plumbing
and manually check the rotation of the
swivel.
16. Reconnect the other gland collet; torque
both gland collets to 40–50 ft-lb (54–68
N-m).
Note: Apply Blue Lubricant (A-2185) to the
gland collet threads before torquing.
17. Pressurize system by closing the manual

bleed valve, opening the manual high-
pressure water valve and restoring electrical
power to the equipment.
WARNING
Care must be taken when pressurizing
any new, rebuilt, or serviced high-pressure
system or component. Increase pressure
slowly [20,000 psi (1379 bar) per minute
maximum]. Apply system pressure for
at least three minutes, and cycle
pressure on and off at least three times.
18. Check for leakage.
CAUTION
Continuous seal leakage can permanently
damage the swivel housing or shaft. Check
for proper seal installation. If tube fittings
leak, remove the tube and rework the
conical surface as described in High-pressure
tubing coning and threading in Chapter 9.
Do not over-torque fittings to stop leakage.

010141-X
Bearing-mounted 90° single axis swivel (010141-1)
Required kits and tools 5. Unscrew the male gland collet from the
high-pressure plumbing leading to the
• 007117-1 3
8-in. swivel seal repair kit nozzle.
• B-2817-1 3
8-in. swivel seal tool
CAUTION
When removing the swivel from the bearing
Disassembly block, do not twist or bend the swivel.
6. Remove the swivel from the bearing block by

WARNING
Place the main electrical disconnect in the OFF pulling the swivel straight out.
position. Bleed down all high-pressure lines. Lock Note: Cover the bearing block to prevent
out the main electrical disconnect and display an
"Out of Service" tag. Failure to do so may result in contaminants from touching the bearings.
equipment damage or injury to personnel.
7. Unscrew the high-pressure collar from the
CAUTION shaft and remove the gland collet.
Service must be conducted in a clean environment 8. Unscrew the thrust/seal collar.
to avoid contaminating system components.
9. Pull the swivel shaft and needle ball
1. Turn off power to the equipment. bearing from the swivel housing.
2. Bleed the high-pressure water from the 10. Insert the swivel seal tool into the thrust
system. plug, engaging the two dowel pins in the
3. Remove the two screws that hold the tubing thrust plug ports.
support bracket to the swivel assembly. 11. Carefully remove the backup ring, seal ring,
swivel seal and ultrahigh-pressure o-ring
WARNING from the seal cavity; discard.
If the high-pressure water line is under
tension, use caution when removing it. Note: Use the swivel seal tool to loosen the
set screw that holds the center pin into the
4. Unscrew the gland collet that connects the tool. Replace the center pin with a #10 tap.
high-pressure water line to the swivel. The tap inserted into the rings will make
them easier to remove.

12. Remove the needle ball bearing and tool. Add a small amount of White Food
thrust/seal collar from the swivel shaft assem- Grade O-ring Lube; this will keep the parts
bly. Discard these parts. from falling off the pin. Make sure the as-
13. Clean the swivel housing and swivel shaft sembly is oriented with the ultrahigh- pres-
thoroughly using clean solvent; blow dry. sure o-ring entering first, as shown.
14. Inspect all sealing surfaces and areas of bear- Note: The backup ring must be flush with
ing contact for galling or heavy wear. Re- the seal cavity edge.
place components as required.
5. Apply Blue Lubricant to the thrust plug and
15. Inspect the needle ball bearing for damage. install it in the swivel housing using the seal
Inspect the inner ring on the swivel shaft. If installation tool.
scored or gouged, replace the bearing.
6. Lubricate the minor diameter of the swivel
Rotate the bearing to feel if there is any dam- shaft and the o-ring with White Food Grade
age to the needle bearing (radial loads) or ball O-ring Lube, then install the o-ring on the
bearings (thrust loads). If the bearing does not swivel shaft assembly.
rotate smoothly, replace it. If the bearing is
good, re-pack it with grease and reuse.
Note: Replace the shaft assembly and oil
seal each time you replace the swivel seal,
seal ring, and backup ring. Replace the nee-
dle ball bearing as needed.
Assembly
swivel seal repair kit.
2. Install the ultrahigh-pressure o-ring on the
minor diameter of the swivel seal. 7. Lubricate the bearing thoroughly with
lithium-based MP grease (or equivalent).
8. Install a new oil seal into the thrust/seal collar.
Orient the oil seal with the lip out, as shown
below.
3. Install the seal ring on the tapered portion of

the swivel seal.
4. Install the seal assembly and seal backup ring
into the seal cavity with the ultrahigh-
pressure o-ring entering first, as shown.
To make installation easier, stack the assem-

bly onto the center pin of the swivel seal

9. Press the thrust/seal collar onto the needle 16. Pressurize the system by closing the manual
ball bearing. Orient as shown. bleed valve, opening the manual
high-pressure water valve, and restoring
electrical power to the equipment.
CAUTION
Do not allow seal leakage to continue—it can
permanently damage the swivel housing or
swivel shaft. Check for proper seal installation.
If tube fittings leak, remove the tube and

rework the conical surface as described in Coning
and threading high-pressure tubing in Chapter 9.
DO NOT over-torque fittings to stop leaks.
10. Reinstall the needle ball bearing and

thrust/seal collar onto the shaft assembly. In- The service procedure is complete.
sert the shaft, minor diameter first, into the
thrust plug.
11. Reinstall the gland collet and high-pressure
collar on the swivel shaft.
12. Lubricate the external bearing race of the
swivel and the roller bearings inside the
bearing mount.
13. Install the swivel assembly in the bearing
mount: determine the swivel's final angle of
placement, then put it in place. Tighten all
other fittings around the swivel placement.
This is done to minimize torsional stress on
the swivel.
14. Tighten the gland collet attached to the
swivel shaft into the high-pressure plumbing
leading to the nozzle. Manually check swivel
rotation. Torque to 40–50 ft-lb
(54–68 N-m).
Note: Apply Blue Lubricant to the gland col-
let threads before torquing.
15. Reconnect the high-pressure tubing and the

tubing support bracket.
WARNING
Take care when pressurizing any new, rebuilt,
or serviced high-pressure system or component.
Increase pressure slowly (maximum of
20,000 psi/1379 bar per minute). Apply system
pressure for at least three minutes, and cycle

C-5152-1 and C-5155-1

The internal design of these two swivels is identical—use this procedure to repair either swivel.
Parallel axis swivel (C-5152-1)
Single axis 90° swivel (C-5155-1)

Required kits and tools

Before performing this service procedure, make 7. Discard swivel seals, backup rings,
sure you have the following: ultrahigh-pressure o-rings, and seal rings.
• B-7447-1 Swivel repair kit Note: Do not discard the seal spacer.
• C-2690-1 Seal installation/removal tool
8. Thoroughly clean all parts and the seal instal-
For more information on these parts, see lation/removal tool in a mild solvent and air
Chapter 10. dry.
9. Carefully remove any backup ring material
build up on the swivel shaft with a fine cro-
Disassembly
cus cloth. Inspect all sealing surfaces and
parts for burrs; remove as required.
WARNING
Place the main electrical disconnect in the OFF
position. Bleed down all high-pressure lines. Lock
out the main electrical disconnect and display an Assembly
"Out of Service" tag. Failure to do so may result in 1. Assemble the new ultrahigh-pressure o-rings
equipment damage or injury to personnel. and seal rings onto the new swivel seals as
shown.
CAUTION
Service must be conducted in a clean environ- Note: There must be a sliding fit between
ment to avoid contaminating system components. both backup rings and the swivel shaft.
1. Turn off the power to the equipment.
2. Loosen the high-pressure glands using two
wrenches. Remove the swivel.
3. Clamp the swivel housing in a soft-jawed
vise. Remove the seal thrust nut.
Note: Do not overstress the swivel housing
when clamping in the vise.
4. Insert the end of the seal installation/

removal tool into the thrust nut cavity. Push 2. Slide the new backup rings, seal assemblies,
the swivel shaft through the high-pressure and spacer onto the lubricated end of the
collar. seal installation/removal tool.
5. Remove the high-pressure collar from the Note: The seal spacer is symmetrical and can
swivel housing. be installed either way; however, all other
6. Insert the end of the seal installation/ parts must be oriented as shown below.
removal tool into the shaft end of the swivel
3. Liberally grease the outside of the stacked
housing and push the seal components out
sealing components with machine oil or light
of the cavity.
grease.

4. Gently insert the assembly into the swivel

housing at the thrust nut end, taking care not
to damage the sealing components.
5. Rotate and gently remove the installation/re-
moval tool.
Note: The sealing components must be
firmly seated in the swivel housing. The
backup ring must be flush with or below the
internal shoulder of the swivel housing.
6. Install the thrust nut and torque by hand. Do

not use a wrench.
7. Lubricate the swivel shaft.
8. Install the high-pressure collar over the
retainer flange.
9. Gently insert the swivel shaft into the swivel
housing.
10. Remove the thrust nut and apply Blue Lubri-
cant (A-2185) to the threads. Install it into
the swivel housing and torque the nut to
20–40 ft-lb (27–54 N-m).
11. Apply Blue Lubricant to the high-pressure
gland threads and torque to 15–25 ft-lb
(20–34 N-m).
12. Determine the final placement angle, then
install the swivel. Tighten all other fittings
around the swivel—this will minimize tor-
sional stress on the swivel.
WARNING
Take care when pressurizing any new, rebuilt,
or serviced high-pressure system or component.
Increase pressure slowly (maximum of
20,000 psi/1379 bar per minute). Apply system
pressure for at least three minutes, and cycle
13. Pressurize the system.

CAUTION
Do not allow seal leakage to continue—it can
permanently damage the swivel housing or
swivel shaft. Check for proper seal installation.
If tube fittings leak, remove the tube and

rework the conical surface as described in Coning
and threading high-pressure tubing in Chapter 9.
DO NOT over-torque fittings to stop leaks.
The service procedure is complete.

CHAPTER 8
Filters
Inline high-pressure water filters are designed to Installing inline filters
maximize orifice assembly life by trapping contami- Inline water filters can be installed anywhere in the
nants suspended in the cutting water. These con- high-pressure water line, but you will get maximum
taminants can be introduced during maintenance, nozzle life if you install the filter as close to the noz-
during system operation (from worn o-rings or zle as possible. Water flow direction is indicated by
seals), or from dislodged mineral scale. If these sus- an arrow on the filter body. Filters are most effective
pended particles are not trapped, it can cause re- if installed horizontally, or with the direction arrow
duced orifice life, clogged orifices, or an orifice pointing down.
failure.
• Filter 000817-1 accepts 38-in. coned and
FLOW has two inline filters, one for ¼-in. tubing threaded stainless steel high-pressure
and one for 38-in. tubing. Each filter assembly in- water tubing.
cludes a filter housing, a replaceable stainless steel
• Filter 000905-1 (with adapters) accepts
filter screen, and adapters for inline installation. 1 -in. coned and threaded stainless steel
4
• ¼-in. inline filter assembly (000905-1) high-pressure water tubing.
8-in. inline filter assembly (000817-1)
3
• • Filter 012832-1 accepts 38-in. coned and
• 5 micron filter assembly (012832-1) threaded stainless steel high-pressure
water tubing.
These filters are for high-pressure water— they are
not intended to replace an inlet water filtration All tubing for UHP pumps must be certified for
system. 60,000 psi (4140 bar) water pressure. Glands and
collars for both inlet and outlet ports are provided.
If you have an 87,000 psi (6000 bar) system, con-
tact FLOW Technical Service for information on
tubing.

Chapter 8. Filters M-127

000817-1 3 -in. inline filter 000905-1 1 -in. inline filter
8 4
Specifications Specifications
Maximum operating pressure . . . 60,000 psi (4140 bar) Maximum operating pressure . . . 60,000 psi (4140 bar)
Filter element: Filter element:
replaceable wire mesh screen . . . . . 105 micron abs. replaceable wire mesh screen . . . . . 105 micron abs.
Pressure drop: * Pressure drop: *
. . . equivalent to 15.4 ft (4.7 m) 3 8-in. OD HP tubing . . . . equivalent to 2.3 ft (0.7 m) 14-in. OD HP tubing
* Operating between 25,000 and 60,000 psi with an * Operating between 25,000 and 60,000 psi with an
uncontaminated filter element uncontaminated filter element

1 A-2838 2 High-pressure gland 1 000806-1 1 Filter housing
2 A-2839 2 High-pressure collar 2 B-1313-1 1 Nozzle body filter screen
3 B-1313-1 1 Nozzle body filter screen 3 A-0792-1 2 High-pressure adapter
4 000806-1 1 Filter housing

M-127 Chapter 8. Filters
012832-1 3 -in. inline filter

8
Specifications
Maximum operating pressure . . . 60,000 psi (4140 bar)
Filter element:
replaceable wire mesh screen . . . . . 105 micron abs.
Pressure drop: *
. . . equivalent to 15.4 ft (4.7 m) 3 8-in. OD HP tubing
* Operating between 25,000 and 60,000 psi with an

uncontaminated filter element
Parts list
1 012826-1 1 Cone
2 012827-1 2 High-pressure collar
3 012828-1 1 Nozzle body filter screen
4 012829-1 1 Filter housing
5 A-13816 1 Filter
6 A-00896-6 1 Roll pin
7 006766-1 1 Adapter nut
8 012950-1 1 Filter insert
9 006765-1 2 Static seal
10 012871-1 1 Outlet nut
11 A-2838 2 Gland
12 A-2839 2 Collar
13 A-00905-12 1 Tube clamp
14 013118-1 1 Label
15 013119-1 1 Label

Chapter 8. Filters M-127
Service procedures
Replacing the inline filter screen

This service procedure is for filters 000817-1 and 4. Thoroughly clean the filter body; air dry.
000905-1. You will need a replacement filter 5. Install the new filter screen in the inlet end
screen before you begin; order part number of the filter body as shown.
B-1313-1.
Note: Apply Blue Lubricant to the threads
CAUTION of both glands.
After initial startup, change the filter screen at
5, 20, 50, and 100 operating hours. From then on, 6. Reinstall the filter assembly in the high-
change them every 400 operating hours. pressure line and torque the glands to
35 ft-lb (47 N-m).
Service steps
Note: Install the filter assembly with the ar-
1. Turn off the intensifier pump. row on the filter body flats pointing in the di-
rection of water flow.
WARNING
Place the main electrical disconnect in the OFF
position. Bleed down all high-pressure lines. Lock Return the intensifier pump to operation and
out the main electrical disconnect and display an check for water leaks.
equipment damage or injury to personnel. CAUTION
If there are leaks, the collars on the high-
2. Unscrew the glands at both ends of the pressure tubing might not be installed
correctly. Remove the gland, reposition the
filter assembly; remove from the high- tubing and/or collar, and re-torque.
pressure tubing.
Do not over-torque the gland to fix leaks.
3. Remove the filter screen from the inlet end
of the filter body and discard.
Note: Use an easy-out or similar tool if the
screen does not come out easily, but do not
force the screen out from the other end.

CHAPTER 9
Accessories
High-pressure tubing (60,000 psi)
O.D. I.D. Flow area Min. bend radius Length

Part # (in/mm) (in/mm) in2/mm2 in/mm ft/meter
A-00144-1 0.250/6.35 0.083/2.11 0.005/3.23 1.25/31.8
A-00144-2 0.375/9.53 0.125/3.18 0.012/7.74 1.75/44.5 AR*
A-00144-3 0.563/14.3 0.188/4.75 0.028/18.1 2.62/66.5
* Comes in 10- and 20-ft lengths. Add length to part number when ordering. For example, A-00144-1-10.
High-pressure tubing (87,000 psi)
3/8 in. tubing for the 7X-6000 pump

013278
Preformed length of tubing, coned and threaded on each end
3/8 in. tubing for 25X-6000 pump

013349
Preformed length of tubing, coned and threaded on each end.
High-pressure tubing shield

Part # O.D. I.D. Length
(in/mm) (in/mm) ft/meter
A-2883 0.406/10.319 0.281/7.144
A-2884 0.500/12.700 0.375/9.525 as required*
A-2887 0.688/17.462 0.563/14.288
* Comes in coils of 300 ft or less.
High-pressure tubing clamps

Tube size Clamp pair Top plate Bolt
part # part # part #
1
4 -in. A-2581 A-2582 A-0026-24*
3
8 -in. A-2585 A-2582 A-0026-24*
9
16 -in. A-9124 ** **
* Additional bolt lengths are available.
** The top plate and bolt are included as part of A-9124.

Chapter 9. Accessories M-127
High-pressure nipples (60,000 psi)
O.D. I.D. Thread Max. thread Length of

Part # in/mm in/mm Type length nipple
in/mm in/mm
A-0781-2 0.250/6.35 0.083/2.11 1
4 -in.-28 UNF L.H. 0.562/14.27 2.75/69.9
A-0781-3 0.250/6.35 0.083/2.11 1
4 -in.-28 UNF L.H. 0.562/14.27 3.00/76.2
A-0781-4 0.250/6.35 0.083/2.11 1
4 -in.-28 UNF L.H. 0.562/14.27 4.00/101.6
A-0781-5 0.250/6.35 0.083/2.11 1 -in.-28 UNF L.H.
4
0.562/14.27 5.00/127.0
A-0781-6 0.250/6.35 0.083/2.11 1 -in.-28 UNF L.H.
4
0.562/14.27 6.00/152.4
A-0781-7 0.250/6.35 0.083/2.11 1 -in.-28 UNF L.H.
4
0.562/14.27 7.00/177.8
A-0782-2 0.375/9.53 0.125/3.18 3

8 -in.-24 UNF L.H. 0.750/19.05 2.75/69.9
A-0782-3 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 3.00/76.2
A-0782-4 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 4.00/101.6
A-0782-5 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 5.00/127.0
A-0782-6 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 6.00/152.4
A-0782-7 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 7.00/177.8
A-0782-8 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 8.00/203.0
A-0782-9 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 9.00/228.6
A-0782-12 0.375/9.53 0.125/3.18 3 -in.-24 UNF L.H.
8
0.750/19.05 12.00/304.8
Measured tip to tip, including threads and cone.

M-127 Chapter 9. Accessories
High-pressure manual valves

(60,000 psi)
A-0785-X A-0787-X A-0788-X A-0789-X A-0790-X
Tube size (O.D.) Minimum

Part # Description in/mm opening
in/mm
A-0785-1 Three-way, two stem, manifold valve 0.250/6.35 0.062/1.57
A-0787-1 Two-way, single stem, right angle valve 0.250/6.35 0.062/1.57

A-0787-3 Two-way, single stem, right angle valve 0.375/9.53 0.062/1.57
A-0788-1 Two-way, single stem valve 0.250/6.35 0.062/1.57

A-0789-1 Three-way, single stem, one-on pressure valve 0.250/6.35 0.062/1.57

A-0789-3 Three-way, single stem, one-on pressure valve 0.375/9.53 0.062/1.57
A-0790-1 Three-way, single stem, two-on pressure valve 0.250/6.35 0.062/1.57

A-0790-3 Three-way, single stem, two-on pressure valve 0.375/9.53 0.062/1.57
Gland nuts and collars are supplied with all valves.

High-pressure fittings (60,000 psi)

These are the most frequently used fittings.
Description Part # Tubing size
Reducer coupling: A-1461 1

4 -in. to 38 -in.
female to female A-2437 3
8 -in. to 9 16 -in.
Adapter: -in. to 14 -in.

A-0792-1 3
8
male to female
Adapter: -in. to 9 16 -in.

A-0792-3 3
8
male to female

A-4691 9
16
male to female

A-1267 1
4
male to female
A-0784-1 1-in.
4
Plug A-0784-2 3-in.
8
9 -in.
A-0784-3 16
A-0775-1 1-in.
4
Elbow A-0775-2 3-in.
8
9 -in.
A-0775-3 16

A-0777-1 1
4-in.
Cross A-0777-2 3 -in.
8
9 -in.
A-0777-3 16
A-0776-1 1
4-in.
Tee A-0776-2 3 -in.
8
9 -in.
A-0776-3 16
A-0780-1 1
4-in.
Straight -in.
A-0780-2 3
8
coupling 9 -in.
A-0780-3 16
A-0778-1 -in.
Bulkhead 1
4
B-8126-1 -in.
coupling 3
8
A-0778-3 9 -in.
16
A-2866 1 -in.
4
Gland A-2838 3 -in.
8
A-3950 9 -in.
16
A-2867 1 -in.
4
Collar A-2839 3 -in.
8
A-3951 9 -in.
16
Anti-vibration A-0689-1 1 -in.

4
Collet and A-0689-2 3 -in.
8
Gland A-0689-3 9 -in.
16
B-5764-1 1 -in.
4
Coned insert A-5713 3 -in.
8
A-9425 9 -in.
16

Connector A-14280 1½ in.
A-0665-6 ¾ NPTF
Pipe nipple A-0665-9 ¼ x 18 in.
A-0665-13 ¾ x 1/2
Connector A-0734-X various

(female)
Hollow hex head A-0641-X various

plug, straight
Connector A-0738-X various

(male)
Conduit connector, A-0566-X various

straight
Water pressure A-14083 ¾ NPT Female

reducing valve

Torque specifications Miscellaneous

for high-pressure fittings
Refer to the table below when specific torque re- A-1456 high-pressure gauge
quirements are not listed in a service procedure. Includes A-1267 14-in. male to 3 8-in. female adapter and
Do not torque mounting bolts and machine screws A-1613 gauge case.
beyond the manufacturer's recommended limits or
those limits described in SAE Standard J174.
The torque for high-pressure water assemblies and
fittings is listed in U.S. Customary System
foot-pounds (ft-lb) and Systéme International (SI)
Newton-meters (N-m).
High-pressure U.S. SI
gland nut ft-lb N-m
1
4-in. 15-25 20-34
8 -in. 35-45 47-60
3
9 -in. 60-75 80-100

16
Note: Threads for all high-pressure connections

must be lubricated with Blue Lubricant (A-2185) A-1623 oil pressure gauge
prior to assembly.
Glycerin filled, 0-5000 psi, stainless steel case.
Dial size 2 ½ in. diameter, ¼ in. NPT, center back mount.
Maintenance videos
Part # Description
A-10377 20X Intensifier Pump
A-10983 Intensifier H.O. Maintenance
A-11047 A-3000 Safety
A-12275 Husky Maintenance
A-12831 Direct Drive Maintenance
A-13686 Eagle Pump Maintenance
A-14847 Garnet Recovery System

Lubricants
Part # Description
Blue Lubricant
A-2185 * (anti-galling compound for all threaded
high-pressure connections.)
White Food Grade O-ring Lube
A-4689
(lubricant for all o-rings.)
200006 Parker Super O-ring Lube
A-4411 Molykote Waterproof Grease
A-8559 Lithium-Based Grease
* FLOW requires the use of Blue Lubricant as an anti-seize,
anti-galling compound on its products. Do not substitute
other lubricants.
Adhesives
Part # Description
A-3202 Loctite #242 (non-permanent)
A-6005 Loctite #262 (permanent)

Locking nozzle mountings

006144-1 Mounting collar
Used on Instajet II nozzle 003850-X. This collar can also be used with on/off valves 010103-1, 012506-1, 012507-1,
012508-X, 012509-1, and 012511-X.

004015-X (obsolete), 006691-1, and 006920-1.


004015-X (obsolete), 006691-1, and 006920-1.

Non-locking nozzle mountings

Used on on/off valves 001322-1, 001817-1, 002656-1, 004015-X (obsolete), and 006920-1.
B-2218-1 3 -in. Instajet nozzle mounting collar

8
Used on Instajet nozzles C-1770-1, C-1852-1 and C-2475-1 and on/off valves C-2728-1 and C-2729-1.


8

8

Service procedures 6. Turn the cutter han-

dle clockwise. Every
three turns of the
Coning and threading handle, turn the
high-pressure tubing notched wheel clock-
You will need the following tools to cone and wise one notch.
thread high-pressure water tubing: Note: Every 15–20
•Hacksaw (for cutting the tubing) turns, empty chips
• Coning and threading tool kit (B-5077-2). and lubricant from
For more information see Chapter 10. the reservoir.
When the notched

wheel is flush against
the body, the coning
operation is complete.
7. Loosen the collet nut and remove the
tubing from the coning tool.
8. Inspect the end of the cone and make sure
the cone face is smooth. Deburr the ID of
the tube.
Threading the tubing

1. Clamp the tubing in a soft-jawed vise.
Coning the tubing

1. Cut tubing to the desired length and deburr
the cut ends.
Note: If using the old tubing for measure-
ment, add 116-in. (1.6 mm) to the overall 2. Slide the threading tool over the tubing
length to allow for cone face off. until the die touches the end of the tubing.
3. Apply pressure to start the cutting action
2. Place the coning tool in a vise and tighten.
while rotating the die holder.
3. Turn the notched wheel clockwise until it
Note: Apply cutting oil generously while
touches the gauge pin.
threading the tubing.
4. Insert tubing through the side of the collet
until the end touches the cutting blades.
Back off the notched wheel (counterclock-
wise) and tighten the collet nut enough to
grip the tubing. Turn the notched wheel
clockwise until the gauge pin is again
contacted.
5. Apply cutting oil (A-3221-5) through the
opening in the top of the cutter support.
Note: Use cutting oil freely while coning.

4. Rotate the die holder until the desired thread 6. Apply Blue Lubricant (A-2185) to the gland
length has been cut (see table threads.
below). 7. Insert the tubing into the connection,
engage the gland, and tighten finger tight.
Note: Torque the gland according to the
high-pressure water fitting torque specifica-
tions located in this chapter of the
manual.
Tubing Size OD Thread Length Thread
National Fine
in. mm in./mm (left hand)
0.250 (¼ ) 6.35 0.562/14.3 ¼-in. (28)
0.375 (38 ) 9.5 0.750/19.1 3

8 -in. (24)
0.562 (9 16 ) 14.3 0.938/23.8 9

16 -in. (18)
Making the tubing connection

1. Deburr the tubing ID.
2. Thoroughly clean the tubing threads with
clean solvent (alcohol), using a wire brush to
remove any metal particles.
3. Slide shielding onto tubing after coning and
threading both ends.
4. Place the gland on the tubing.
5. Screw the collar on the threaded end.

Note: These are left-hand threads.
There should be 0.23 in. (5.8 mm) between

the end of the cone and the edge of the col-
lar. Turn the collar until 2–3 threads show be-
tween the end of the cone and the edge of
the collar.

Servicing the high-pressure manual valve 7. Slide the packing off the stem tip; discard
packing and retainer washer. Inspect body
This service procedure is for all high-pressure man-
and remove any packing.
ual valves.
8. Remove the nozzle body from the vise; clean
Required service kits body and stem thoroughly, and air dry.
9. Clean the nozzle nut assembly, using the ser-
• for minor repairs: Valve stem packing kit vice procedure for cleaning the orifice (see
(A-1416) Chapter 6).
• for major repairs: High-pressure manual valve 10. Inspect the valve stem tip for grooves or flat-
rebuild kit (A-3835)
tening. If damaged, replace the valve.
Service steps 11. Install the new packing and retainer washer
on the valve stem in the order shown.
1. Close the valve that supplies high-pressure
water to the nozzle. 12. Place the anti-rotation bracket on the valve.
2. Open the nozzle valve to bleed the high- 13. Place the nozzle body in a soft-jawed vise.
pressure lines up to the nozzle. 14. Install the valve in the nozzle body and
3. Remove the nozzle assembly from the torque the valve stem nut to 35 ft-lb
mounting block and place in a soft-jawed (47 N-m).
vise. 15. Remove the nozzle body from the vise.
Note: If you can't remove the nozzle, look 16. Install the nozzle nut assembly on the
for a snap-ring under the mounting block. nozzle body and torque to 35 ft-lb (47 N-m).
17. Mount the anti-rotation bracket on the valve
4. Unscrew the nozzle body from the nozzle
stem nut and install the bracket screw and
nut; remove the nut from the vise and place
washer.
the nozzle body flats in the vise.
18. Reinstall the nozzle assembly on the
5. Unscrew and remove the anti-rotation
mounting block.
bracket screw. Place screw and washers in a
clean container.
6. Unscrew the valve stem from the nozzle
body. Keep the anti-rotation bracket.

Notes

CHAPTER 10
Kits and tools
Repair kits and service tools for waterjet systems are listed in the manuals that come with each system. Be
sure to check your pump, intensifier, and other equipment manuals shipped with your system for more kits
and tools.
Nozzle repair kits

007126-1
for Instajet II nozzle 003850-1
1 003832-1 1 Backup ring
2 003831-1 1 Nozzle seal
4 003838-1 1 Stem bushing
5 003830-1 1 Poppet assembly
007126-2
007126-4
007126-3
007126-5

Chapter 10. Kits & Tools M-127
Instajet nozzle high-pressure seal On/off valve repair kits

B-5841-1 001959-1 for On/Off Valve I (old)
for Instajet nozzles C-1770-1, C-1852-1, C-2475-1 for on/off valve I: 001322-1, 001817-1, 002656-1,
004015-X, 006920-X, 006691-1 (obsolete)
1 A-0275-006 1 O-ring
1 006933-1 1 Poppet seat
2 B-1931-1 1 Seal
2 006934-1 1 High-pressure valve poppet
3 B-1932-1 1 Seal backup ring
3 001328-1 1 High-pressure valve seal
4 001337-1 1 Seal backup ring
5 A-0275-006 1 O-ring
6 A-0275-014 1 O-ring
7 — 3-in. 3
16 -in. wooden dowel
010200-1 for On/Off Valve II

for on/off valve II: 010103, 012506, 012507, 012508,
012509, 012511
1 003831-1 1 Seal
4 006933-1 1 Poppet seat
5 010105-1 1 Poppet
6 A-0275-014 1 O-ring
7 B-8075-007 1 Silicone dip o-ring
8 — 3-in 3
16 -in. wooden dowel

M-127 Chapter 10. Kits & Tools
On/off valve repair kits…
A-3835 B-5741-1 High-pressure valve repair kit

for valves A-0785, A-0787, A-0788, A-0789, A-0790 for valves C-2728-1 and C-2729-1
1 1 Stem assembly 1 B-5975-1 1 Adapter
2 1 Packing gland 2 A-4241 1 Oil seal
3 1 Backup washer 3 A-0274-6 1 O-ring
4 1 Packing washer 4 B-5703-1 1 High-pressure valve seat
included:
5 1 Packing set 5 B-5702-1 1 High-pressure valve stem
6 1 Handle 6 B-5701-2 1 High-pressure seal
NS 1 Locking device 7 B-5723-1 1 Cone seal
NS 1 Screw 8 B-5700-1 1 Bushing
NS A-1416 1 Valve stem packing kit 9 A-0275-008 1 O-ring
(see below)
A-1416 Valve stem packing kit

See above
A-1416-1 2 Steel packing
A-1416-2 2 Nylon packing
A-1416-3 1 Leather packing
A-1416-4 1 Retaining washer

Poppet repair kits

B-6280-1
for Instajet nozzles C-1770-1 and C-2475-1
1 C-2724-1 1 Poppet assembly
5 B-6231-1 1 Poppet insertion tool
6 B-5841-1 1 Instajet seal kit
B-6281-1
for Instajet nozzle C-1852-1
1 C-2724-1 1 Poppet assembly
4 B-6231-1 1 Poppet insertion tool
5 B-5841-1 1 Instajet seal kit

Swivel repair kits

007117-1 3
8 -in. swivel repair kit 007715-1 Inline swivel repair kit
for swivels 010141-1, 010140-1, 010142-1, 010143-1 for swivel C-2515-1
1 B-1791-2 1 Swivel seal 1 A-0275-017 1 O-ring
2 B-8075-009 1 Ultrahigh-pressure o-ring 2 A-2007 1 Oil seal
3 B-1790-1 1 Swivel seal ring 3 A-2009 2 Bearing race
4 B-1789-1 1 Backup ring seal 4 A-2010 1 Roller bearing
5 007116-1 1 Swivel shaft assembly 5 B-1789-1 1 Backup seal ring
6 A-0275-017 1 O-ring 6 B-1790-1 1 Swivel seal ring
7 A-2007 1 Oil seal 7 B-1791-2 1 Swivel seal
Note: Also purchase swivel shaft assembly 007116-1 as 8 B-8075-009 1 Silicon o-ring
needed.
B-2281-1 3
8-in. swivel seal repair kit
for swivels C-1589-1, C-1590-1, C-1760-1, C-2515-1
A-0275-017 4 O-ring
A-2007 4 Oil seal
A-2009 8 Bearing race
A-2010 4 Bearing
B-1789-1 4 Backup seal ring
B-1790-1 4 Seal ring
B-1791-2 4 Swivel seal
B-8075-009 4 Ultrahigh-pressure o-ring
Contains parts to repair 2 dual swivels or 4 single swivels.

B-5910-1 1
4 -in. swivel repair kit
for swivels B-5490-1 and B-5725-1

1 B-1790-1 1 Seal ring
2 A-0275-007 1 O-ring
3 B-5492-1 1 1
4 -in. swivel ring backup seal
4 B-5493-2 1 1
4 -in. swivel seal
6 A-3823 1 Thrust washer
7 A-3822 2 Thrust bearing
B-7447-1 Swivel repair kit
for swivels C-5152-1 and C-5155-1

1 B-5694-1 2 Seal backup ring
4 B-1790-1 2 Seal ring

Tools
B-5716-1 High-pressure valve tool 007127-1 Poppet removal tool
For on/off valves C-2728-1 and C-2729-1 For Instajet II nozzle 003850-X
B-6231-1 Poppet removal tool

For Instajet nozzles C-1770-1, C-1852-1, C-2475-1
1 B-5915-1 1 Seal removal tool

2 B-5914-1 1 Seal insertion tool
3 B-5913-1 1 Tool holder
Although B-6231-1 and 007127-1 are nearly identical,
4 A-0509-4 2 Set screw they are not interchangeable. Before ordering, confirm
which tool is right for your Instajet or Instajet II nozzle.
B-5982-1 High-pressure seal tool C-2690-1 Swivel seal tool

For Instajet nozzles C-1770-1, C-1852-1, C-2475-1 For swivels C-5152-1 and C-5155-1
1 A-4358 2 Plunger spring

2 B-5981-1 1 Tool cover
3 C-2705-1 1 Instajet nozzle tool

C-2691-1 Swivel seal tool B-6263-1 Swivel puller

For swivels B-5490-1 and B-5725-1 For swivels B-5490-1 and B-5725-1

2 B-6261-1 1 Spreader
3 B-6262-1 1 Body-seal puller
B-2817-1 3 -in. swivel seal tool

8 A-1275 Strap wrench
For swivels 010141-1, 010140-1, 010142-1, 010143-1, Used to remove cylinders from standard FLOW intensifiers.
C-1589-1, C-1590-1, C-1760-1, C-2515-1 Also see A-6333.
1 A-0352-8 2 Dowel pin

2 B-2816-1 1 Handle
A-6333 Girth wrench
3 B-2814-1 1 Body
Used to remove cylinders from standard FLOW intensifiers.
4 B-2987-1 1 Pin Also see A-1275.
5 A-0502-3 1 Set screw
6 A-0504-4 1 Set screw

A-3403 Tool kit

Used on many small high-pressure components.
1 A-3403-2 1 Combination wrenches

2 A-3403-3 1 1 14 -in. end wrench
3 A-3403-4 1 13
16 -in. end wrench
4 A-3403-5 1 Slide T-handle
5 A-3403-6 1 1-in. torque wrench
2
6 A-3403-7 1 Hex key set

7 A-3403-8 1 Screwdriver set
8 A-3403-9 1 1-in. drive socket
2
9 A-3403-10 1 Rubber mallet

10 A-3403-11 1 Slip joint pliers
11 A-3403-12 1 Tool box
12 A-3403-13 1 Offset screwdriver
B-5077-2 Coning & threading tool kit

Used on all high-pressure tubing.
A-3402 1 Bushing guide, 9 16 -in.
A-3401 1 Bushing guide, 38 -in.
A-3400 1 Bushing guide, ¼-in.
A-3399 1 Threading die, 9 16 -in.
A-3398 1 Threading die, 38 -in.
A-3397 1 Threading die, ¼-in.
A-3396 1 Threading handle
Coning tool:
A-14345-2 1 ¼-in. collet
A-14345-3 1 3
8 -in. collet
A-14345-4 1 9
16 -in. collet
A-14345-5 1 Cutting lubricant
A-14345-6 1 ¼-in. bit/blade
A-14345-7 1 3
8 -in. bit/blade
A-14345-8 1 9
16 -in. bit/blade
A-14345-9 1 Deburring tool

Notes

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SMALL HIGH-PRESSURE

Rev. I — September 2001

2 © Flow International Corporation

Product registration M-127 (Rev. I)

Return this form to receive future updates to this manual.

Is the information contained in each chapter well organized? Yes [ ] No [ ]

Is the page layout well-suited to the material being presented? Yes [ ] No [ ]

© Flow International Corporation 3

Is there any information that should receive more emphasis? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 © Flow International Corporation

Small High-Pressure Components

© Flow International Corporation 5

Specifications & parts lists Non-locking nozzle mountings

6 © Flow International Corporation

Flow International Corporation 7

Warnings, cautions, and notes

8 © Flow International Corporation

© Flow International Corporation 9

Safety tips • Be alert at all times when working around the

10 © Flow International Corporation

Waterjet cutting system High-pressure waterjet cleaning tools

© Flow International Corporation 11

12 © Flow International Corporation

Emergency medical information

FLOW INTERNATIONAL CORPORATION

This person has been working with water jetting at pressures to

© Flow International Corporation 13

14 © Flow International Corporation

The most likely causes of each problem are listed

© Flow International Corporation 15

4. Leakage from nozzle body weep hole

16 © Flow International Corporation

5. Leakage from nozzle

© Flow International Corporation 17

18 © Flow International Corporation

• C-1161-1 for 3 8-in. tubing

© Flow International Corporation 19

Specifications and parts lists

C-1161-1 3 -in. nozzle assembly

Nozzle bodies available for C-1161-1 Parts list

Specifications 6 004519-6 1 Orifice mount assembly*

20 © Flow International Corporation

Nozzle bodies available for C-2216 Parts list

© Flow International Corporation 21

Nozzle bodies available for C-2455-X Parts list

22 © Flow International Corporation

Replacing nozzle filter screens

6. Thoroughly clean the nozzle body; air dry.

7. Install the new filter screen in the nozzle

© Flow International Corporation 23

24 © Flow International Corporation

© Flow International Corporation 25

On/off valve assemblies Installing on/off valves

Maximum flow rate through on/off valve assem-

26 © Flow International Corporation

Standard on/off valves

Specifications Parts list

Valve weight . . . . . . . . . . . . . . . . . . . . . . 7 lb (3.17 kg) * A parts list is located in this chapter.

Optional mounting collar. . . . . . . . . . . . . . . B-6060-1*

* Chapter 9 has more information on mounting collars. A

© Flow International Corporation 27

C-2729-X Normally open

Specifications Parts list