CNC Ultra-high pressure waterjet
Maintenance Manual
First, cutting table
Maintenance
1. The machine should be operated by full-time personnel.
2. Inspect the fixture of all screws.
3. Inspect the fixture of all linear rolling guide and ball screw. There should not be axial
float of ball screw.
4. The maintenance of rolling guide and ball screw are very important. Users should use
coal oil to clean them at least one time every month .At the same time add lubricant.
5. When clean the linear guide and ball screw on X-axis, you should remove the protecting
cap on crossbeam.
6. When clean the linear guide and ball screw on Y-axis , you should dismantle the deck
plate and protecting cap.
7. Moreover, check the fastening piece of linear rolling guide and ball screw to see whether
it is firm enough . There should not be axial float of ball screw.
8. All the linear rolling guide and ball screw are equipped with lubricative components. In
principle, fuel the machine through manual lubricant pump after it has been working for
2 hours . The lubricant should be No.20 machine oil. When the oil surface level is lower
than the fuel level denotation, please replenish oil immediately.
9. Before working, fill the oil feeder of air supply triplet with 2/3 lube, the lube should be
ISO VG32 or sister lube.
10.The machine should not be kept running for over 24 hours.
11.Clean abrasive deposition in water tank at regular intervals.
12.The users must clean powders and leftover after working.
13.Viruliferous software is strictly prohibited. Make a practice of virus check-up and clear
the hard disk shiver regularly. Please clear unused data to guard against insufficient
hard disk space and virus infection.
14.You’d better not install other software to guarantee sufficient hard disk space and virus
infection.
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15.The power supply of control system must be stable enough. If possible, fix a clean
power supply keep away from high-powered power supply. If the electro-circumstance is
poor, please provide regulated power supply, otherwise the machine can not work
normally.
Troubleshooting
No. Symptoms Reasons Way to solve
1 Improper computer parameter Adjust parameters
Lose step Electric motor failure Inspects the line
Drive breakdown Replace the drive
Mismatching mainboard of Replace the computer
computer
Incorrect insertion of card or Reinsert or replace the card
problematical “IO” card
2 Unable to enter The softdog has not been Reinsert the softdog or
into control inserted well replace mainboard
software
No power supply The mains switch in electric Turn the switch to “ON”
3 switch box is not on
Inspect the electric switch
The power lead plug falls off box and the connecting
power lead plug
Certain axis has Drive breakdown 1．Press button on the axis
4 no motion and observe indicator light
to see whether it is working
2． Exchange socket
connector on the axis with
another normal axis
Motor failure Method as above
The socket connector has not Inspect socket connector to
been connected well see whether it is firm
5 After copy of Floppy drive failure results in Use network card to
document, the data loss connect the two computers
emulation tip as much as possible to
indicates data avoid floppy drive copy
error or false
emulational figure CPU Errors Inspect the mainboard
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Second, intensifier pump
Maintenance
1. Change hydraulic oil and clear oil box once half a year (the used oil could not be used
again). The hydraulic oil should be homemade No.46~68. Apply No.46 in winter and
No.68 in summer. When clear the oil box, first clear up the box, open rear side-panel on
intensifier pump, get down the cover and use coal oil to clean. You should use towels
which are not easy to lose hairs to avoid pollution.
2. Clean the oil box, in the mean time clean oil filter
3. Always check the signal lamp of oil filter, when the lamp is ON ,clear the oil filter
immediately
4. When the oil temperature ≥45℃, the cooling system will start automatically (Warning :
the temperature of cooling water must below 30℃)
5. Check the oil level often. If it is close to the lower limit, please refill.
6. Oiling transmission parts of the machine every day.
7. Always check the dust guard. If worn or damaged, please treat it in time to prevent
damage of transmission parts
Troubleshooting
As to hydraulic and driving part（table I）
Symptoms reasons Way to solve
Jammed oil filter Clean or change oil filter
extremely sticky oil Use appropriate oil
Oil pump generates
noise.
Airtight oil box Clean air filter
Oil surface is low Add oil to upper limit
The oil suction pipe leaks air Replace the pipe
Foam in oil
The seals of oil pump shaft leak air Replace the seals
The oil pump wears out or damaged Repair or renew
The oil pump is
overheating Oil viscosity excessively low, high or Use recommended hydraulic
oil deterioration oil or refill new oil
The spring or the poppet is damaged Replace or clean damaged
The overflow valve or the damping hole is stopped up parts
whistles
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The oil temperature is The flow rate of overflow valve is too Lower flow rate to match
excessively high high high pressure system
The electro-liquid shift poppet is Clean valve core
caught
The intensifier does
not shift The electro-liquid shift valve has not Fix the breakdown to make
received a signal the electro-liquid shift valve
receive signals
The electromagnetic overflow valve Clean the overflow valve or
core is clogged by foreign materials restore the electrical signal
The hydraulic system or does not have electrical signals
does not have
pressure
The oil filter door is not open Open the oil filter
The overflow valve electro-magnet Fix the breakdown to make
The hydraulic system does not have a signal or the valve the electro-magnet receive a
does not release core is caught signal or to clean the overflow
pressure valve
The oil pump flow rate is not enough or Adjust the oil pump flow or
When shifting , the oil the bidirectional and unidirectional adjust the bidirectional and
pressure gauge throttle valve have not been adjusted unidirectional throttle
swings in a big way well.
The bidirectional and unidirectional Adjust the bidirectional and
The shift speed of left throttle valve have not been adjusted unidirectional throttle valve
and right are different well.
※Judging method : Oil pump temperature is 20 ℃ higher than oil temperature in the tank.
☆May use hands to push the electromagnetic directional control lever, if the intensifier
can commutate ,indicating troubles leave in the electrics.
As to the high pressure system (table II）
Symptoms reasons Way to solve
The intensifier does not The energy converter is
Clean or replace
shift jammed, or see table I
Adjust bidirectional and
The intensifier knocks Low inlet water pressure into
unidirectional throttle valve,
severely the intensifier
eliminate the noise
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The high-pressured water
Energy converter damage Replace
disperses
The energy converter is Clean or replace
jammed (this time hydraulic
system has pressure)
No high pressure water
comes out
The low pressure water pump
Fix
does not supply water
The high pressure filter sieve
Fix
is clogged
Inspect high pressure pipe
The high pressure system
connection and all weep
leaks
holes, remove leakage
The hydraulic system drop of Remove the reason for drop
pressure or unmatched of pressure or adjust the
pressure hydraulic pressure higher
High pressure system
drop of pressure
Adjust the flow of hydraulic
The flow rate of hydraulic oil
pressure oil pump to match
pump is not enough
the high pressure system
Hot check valve indicates Repair or replace the hot
leakage check valve
Hydraulic cylinder piston seals
Replace
damage
The energy convertor is Take apart and washes or
The ultrahigh pressure
jammed replace
cannot release
The high-pressured bleed Turns on the high-pressure
down valve is not open bleed down valve
Judging method: Exchanges
Water leaking from high the end bell, if still leakage at
pressure cylinder end
the corresponding side,
bell and high-pressured If the seals are undamaged,
showing that the high
cylinder interface one of the two parts is broken
pressure cylinder is damaged.
Otherwise the high pressure
cylinder end bell is damaged.
Water leaking from Plunger seal is damaged Replace
cylinder end bell weep
hole
Water and oil leaking from Piston rod is damaged Replace the piston rod and
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end bell weep hole D3 Y-ring
Water leaking from bleed
Worn seals Replace the seals
down valve body
Judging method: Determine
first when lose pressure, the
oil piston is moving to which
direction. When lose pressure
and the piston is moving to
the left, inspect the low
One side of the intensifier pressure check valve on the
Check valve assembly failure
does not have pressure left and the high pressure
check valve on the right.
Otherwise, inspect the low
pressure check valve on the
right and the high pressure
check valve on the left.
Replace the damaged parts
Judging method: Determine
first at which direction the oil
piston moves faster. If it
moves faster to the left,
inspect the low pressure
The shift speeds of left check valve on the left and the
Check valve assembly failure
and right are different
high pressure check valve on
the right. Otherwise inspect
the low pressure check valve
on the right and the high
pressure check valve on the
left. Replace the damaged
parts.
When replace the cylinder plunger seals ,you must open the cylinder end bell, for guards
against the liquor to drip massively. Please judge the seals of which side is damaged first.
Move the piston to the damaged side, at the same time observes the piston position
indicating lamp, once the lamp is on (indicate the piston arrived at the end).,stop moving
immediately, At this time ,the liquor on this side has returned to the oil tank.
◆At this time the intensifier does not show pressure in movement, only show at the
moment of shift
◆This time the hydraulic system and the high pressure system all indicate the pressure,
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3.As to cutting ( table III）
Symptoms reasons Way to solve
The nozzle or orifice is not The replacement energy switch
good enough or drop of or sees the table II
pressure
The high pressure filter Clean or replacement high
Cutting effect not good screen is clogged pressure sieve
Inappropriate abrasive Adjust abrasive quantity to right
quantity amount, avoid oversized and too
little abrasive (the negative
pressure must between-0.005～
-0.01Mpa）
The negative pressure is Inspect the abrasive pipe to see
insufficient whether it leaks
NO abrasives Foreign substances in Remove（for details see part Ⅶ）
abrasive-control system
High negative pressure Adjust negative pressure to
resulting jam of the nozzle normal
Needle-valve Replace
over-damaged
Excessive abrasives
Over negative pressure Adjust to normal
Note : When mark the material without cutting all the way through, This is typically
accomplished by reducing pressure, reducing abrasive flow rate or increasing feed rate.
(the pressure is depend on materials)
1. Abrasive valve short of abrasives
Reason: Maybe the abrasives is unclean and foreign substances are mixed in the
abrasives. For example: the throttle is stuck by debris or wastepaper etc. Judging method :
inspect negative pressure gauge (1) negative pressure is lower than the fixed value.
This indicates foreign substances is in the throttle seat of nut in abrasive box outlet. (2) No
negative pressure, then foreign substances or overmuch abrasives are stuck between
abrasive valve and abrasive delivering pipe coupling. Solution: if it is the first case, twist
the welded fitting nut off, lay down abrasive valve, dismantle the throttle seat with
screwdriver, Thus foreign substances can flow out along with abrasives. If foreign
substances are oversize then dismantle the abrasive hopper to clean foreign substances. If
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it is the second case , dismantle the abrasive valve connection, abrasive delivering pipe
and its coupling to eliminate foreign substances.
2. Backwater
Reason:1)The nozzle is jammed, maybe foreign substances are mixed in the nozzle.
2) The bleed down valve failure .Solution:1) Disassemble cutting head and take out nozzle
to clean foreign substances or install the nozzle reversely and use high pressure water to
dash out foreign substances .2) Inspect the needle or insert in on/off valve to see whether
they are damaged, if they are ,please replace.
3. The intensifier generates high pressure, but there is no high pressure water comes out
of the cutting head
Reason:1) Maybe diamond orifice is stuck by foreign substances. 2) The high pressure filter
screen is jammed.
Solution: Disassemble the cutting head, take out diamond orifice and blow with mouth or air
compressor . If it is airproof, use tiny steel wire to insert into the focus of orifice to clean
foreign substances.2) Take out and clean the high pressure filter screen.
4. Water from the cutting head is dispersive, coarse and not concentrated
Reason: May be diamond orifice is damaged badly
Solution: Replace the diamond orifice
5. If it is short of water supply and causes water inlet of water pump intake of air, you must
release air in the water inlet of water pump and fill the water hole over the water pump
head .
6. If something unexpected happened and the nozzle is broken , but you still want to use
the broken nozzle, please smooth the fracture and must be the same taper as the
original nozzle.
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