#7030 SFP/DFP Rev.

B 040330 CoolJ et Operation Manual

1
High Pressure Coolant System
Cool J Cool J Cool J Cool J Cool J et Syst ems et Syst ems et Syst ems et Syst ems et Syst ems 2900-A Sat ur n St r eet
Br ea, CA USA 92821-6203
Phone (714) 577-9262 Fax (714) 577-9271
Email [email protected] [email protected] [email protected]
Web www.cooljet.com
Operation
Manual
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
2
This document is based on information available at the time of publication. While CoolJet Sys-
tems has made every effort to provide current and accurate information, this manual may not cover
all contingencies regarding installation, operation and maintenance.
CoolJet Systems assumes no responsibility for third-party or original equipment manufacturer
(OEM) documentation used for this publication or included as supplemental information.
Copyright 2000 CoolJet Systems, Inc. This publication may not be reproduced by any means, in
whole or in part, without the express written consent of CoolJet Systems. All other registered
trademarks mentioned in this publication are the property of their respective owners or companies.
Warnings and Notices Used in this Publication
Warning notices emphasize that hazardous voltages, electrical currents, temperatures or other con-
ditions are associated with the equipment or its operation. These conditions can cause personal
injury or death.
Caution notices alert operators or maintenance technicians that equipment might be damaged if
procedures are ignored.
Notes call attention to information that affects proper operations or servicing of equipment. This
designation is also used for miscellaneous information that does not fall under the two previous
categories.
Safety Precautions
Read and follow all instructions and safety warnings in this manual prior to installing or
operating this high pressure system.
Always wear safety glasses when operating high pressure.
Have all machine guards in place before activating high pressure.
Never adjust the Pressure Regulating Valve to increase coolant pressure without a properly
sized discharge orifice installed. ( .097 [2.5mm] max for 60 Hz operation, .089 [2.3mm]
max for 50 Hz operation)
Adjust coolant nozzles only when the system is not in operation.
Never put any part of your body in front of the coolant stream.
Never direct the coolant stream towards anyone at anytime.
Not i c e & Saf et y Pr ec aut i ons
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
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Table of Contents
Notice & Safety Precautions ----------------------------------------------------------------------- 2
Introduction ------------------------------------------------------------------------------------------4
Contents & Specifications of The CoolJ et System----------------------------------------------5
Installing The CoolJ et System
Overview of System Operation----------------------------------------------------------- 6
Mechanical Installation-------------------------------------------------------------------- 7
Electrical Installation----------------------------------------------------------------------- 9
Operating The CoolJ et System
Startup Procedures - SF Models-------------------------------------------------------- 12
Startup Procedures - DF Models-------------------------------------------------------- 13
Pressure Calibration Procedures-------------------------------------------------------- 14
CoolJ et Controller and System Indicators--------------------------------------------- 15
Optimizing The CoolJ et System
Pressure & Orifice Sizing --------------------------------------------------------------- 15
Maintaining The CoolJ et System
Filter Replacement - SF Models-------------------------------------------------------- 17
Filter Replacement - DF Models ------------------------------------------------------- 18
Routine Maintenance--------------------------------------------------------------------- 20
Troubleshooting--------------------------------------------------------------------------- 22
Repair Instructions ----------------------------------------------------------------------- 24
Spare Parts--------------------------------------------------------------------------------- 31
Appendix A: Electrical Documentation------------------------------------------------------ 37
Warranty -------------------------------------------------------------------------------------------- 38
Space for Notes------------------------------------------------------------------------------------ 39
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
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Introduction
To Your
CoolJet High Pressure Coolant System
Applying a CoolJ et system to an existing machine tool shows you can teach old dogs new tricks.
The impact in performance can be so dramatic, you may have to rewrite your shop standards.
Feed rates, RPM, and tool life can reach levels never imagined possible by previous generations
of machinists.
High pressure coolant from the CoolJ et system, when directed into the cutting zone, forcibly
ejects the chips. This results in better surface finishes, faster feeds, and reduced tool breakage.
The CoolJ et system also reduces heat at the cutting tool edge. This results in longer tool life, and
lubrication of the cutting tool. In other words, faster machining.
The bottom line for CoolJ et Systems... is to make your bottom line look better. Feel free to
contact our CoolJ et Customer Support. We have years of experience in helping machine shops
just like yours outperform the competition. Teaching old (or even new) machines new tricks is
what we do best.
Sincerely,
THE COOLJET TEAM
T TT TTel e el e el e el e el ephone phone phone phone phone
714-577-9262 714-577-9262 714-577-9262 714-577-9262 714-577-9262
F FF FFax ax ax ax ax
714-577-9271 714-577-9271 714-577-9271 714-577-9271 714-577-9271
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#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
5
Cont ent s & Spec i f i c at i ons
Specifications 60Hz 50Hz
Flow Rate: gallons/min. (liters/min.) 8.0 (30) 6.6 (25)
Motor Horsepower (KW) 6.0 (4.4) 5.0 (3.7)
Voltage, Three Phase 208-230 190
Total Connected Amps 16.5-16.0 18.0
Required Inlet Pressure 20-60 (1.4-4.1) with system running
Maximum Discharge Pressure, PSI (Bar) 1000 (70)
Discharge Fitting, Male 3/4 in. (-12) J IC 37 (2x)
Inlet Hose Fitting 1 (-16) J I C 37
Acoustic Noise (Decibels) 74db
Footprint (mm) 17x33x60H (432 cm x 838 x 1524 cm)
Shipping Weight SF Models 450 lbs (205 kg)
Shipping Weight DF Models 500 lbs (227 kg)
Paint Powder Coat, Grey
Note: Dual rated motor may be operated at 50Hz or 60Hz. Motor RPM and discharge
volume, however, will be affected.
Please verify that you have received
all of the components listed.
Qty Description
1 CoolJ et Pump Assembly, Including:
Electrical Controller, One (SF) or Two (DF)
High Capacity Filter with Elements installed,
Interface Cables
1 Interface Hose set (Inlet, Bypass, Drain hoses)
1 Pressure Calibrating Orifice
1 High Pressure Warning Label
1 Quart of 15W-50 Full Synthetic Motor Oil
1 Oil Drain Pan & Oil Funnel
1 Spare Filter Bag per Filter: Felt 10 mic.
1 Filter Hold-Down Device (wire) per filter
45.5
(115cm)
Minimum
26.5
(67.5cm)
Area for
Clearance
Filter
Service
8.88
(22.5cm)
88.5
Minimum
(225cm)
16.5
(42cm)
Minimum
Area for
Clearance
Filter
Service
Air Purge Valves
Drain Valve
Assemblies
Filter
Selector
Valves
Output
Gauge
Output
Gauge
Inlet
Gauge
Inlet
Gauge
Clean Out
Plug
Safety
Strainer
Gauge
Inlet from
Supply Pump
Oil Drain Cap
Fitting
Removable
Access
Panels
Bypass Pressure
Regulating Valve
Electrical
Controller
Discharge
Front View Rear View
Differential
Pressure Switch
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
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Syst em Consi der at i ons:
Safety Valve: CoolJ et systems generate pressure by positive displacement. A High Pressure Regu-
lator Valve is provided as a safety valve, to control the maximum system pressure and to prevent
over pressurization. Incorrectly adjusting the regulator setting may void warranty and could result
in personal injury or damage to the pump or your machine tool. Do not remove the High Pressure
Regulator valve from your system.
The Manufacturer does not assume any liability or responsibility for the misuse
of a customers high-pressure system.
Pump Lubrication: Change oil after first 50 - 100 hours of operation and every 500 hours there-
after. Fill crankcase with approximately 35 oz. (1.03 liters) of 15w-50 full synthetic motor oil.
Refer to the section on changing the pump oil for details. DO NOT RUN PUMP WITHOUT OIL
IN THE CRANKCASE.
Inlet Pressure: A positive head pressure must be maintained to avoid problems associated with
cavitation. In so doing, a dedicated supply pump is required to feed coolant to the 70-30 filter inlet.
The supply pumps pressure capability should be determined prior to its installation. The CoolJ et
system has a system inlet pressure rating of 60 psi (4.1 Bar) maximum.
For supply pumps that provide excessive inlet pressure, CoolJ et offers the #2503 Inlet Pressure
Reducing Kit for regulating to 60 psi (4.1 Bar).
Filtration: The CoolJ et requires coolant be filtered to a minimum of 500-micron. High capacity
filter bag elements rated at 100, 25, 10 or 5-micron are available from our factory. Pleated cartridge
elements are also available and are rated at 50, 25 or 10-micron.
Coolant Viscosity: The CoolJ et system may be used to pump coolants or oils of viscosity up to 500
SUS.
Considerations before Installation
A. Before installing the CoolJ et system, verify that your entire coolant delivery system (hoses,
valves, fittings, coolant couplings) is capable of supporting your desired operating pressure.
B. For best results, replace contaminated coolant and clean out machine reservoir to remove accu-
mulated chips and debris.
C. Your CoolJ et uses both tapered pipe (NPT) fittings and 37
o
J IC hydraulic fittings. The J IC
fittings are designed to seal against pressure and vacuum leaks without the use of any pipe
sealant compound. For threaded NPT connections, use curing pipe thread sealant (such as Loctite
#565) or PTFE liquid/tape. If tape is used, do not wrap beyond the last thread to avoid tape from
being lodged within the system.
D. If you have any questions or require factory assistance during installation, please con-
tact CoolJet Customer Service.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
7
The CoolJ et system should be located to minimize the required hose lengths between the
CoolJ ets pump and your machine. Verify the CoolJ et interface cable length is adequate to
reach machine tools electrical cabinet.
Position the pump assembly to provide adequate work space and allow room for checking
the oil level, changing oil, inspecting pressure gauges, and servicing filters.
I nst al l i ng The Cool Jet Syst em
Locating The Pumping System
INLET PLUMBING
It is highly desirable to avoid creating turbulence when pumping coolants, please pay particular atten-
tion to the following when connecting an inlet line.
Do not use inlet hoses or components (valves, fittings, etc.) smaller than 1.5 (38mm) I.D.
If elbows are required in the inlet plumbing, 45 fittings are preferred to 90 fittings. Try to arrange
sweeping hose curves if 90 hose routings are required.
Use thread sealant on any NPT fittings in the inlet plumbing. Any leaking joints can allow air to be
drawn into the system and cause cavitation. Sealant is not required for JIC 37 fittings.
Mount the Low Pressure Plumbing as follows; the pipe support clamp should be fastened to the top of
the machines coolant reservoir. A check valve is used to maintain fluid prime to the transfer pump.
Connect one end of the 1.5 (38 mm) diameter hose to the support clamp assembly. The other end
should be connected to the CoolJet coolant inlet. Make sure all hose clamps are tight.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
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Operator Warning Label
Affix the MACHINE WARNING LABEL to your ma-
chine, preferably at eye level on the door of the ma-
chine, providing maximum visibility to operators.
After completing the installation instructions, you will
be ready to start up your CoolJ et System. Before
continuing, be sure you have read the Precautions
Section.
I nst al l i ng The Cool Jet Syst em
High Pressure Hose Guidelines
Use at least 3 ft. of flexible hose between the CoolJ ets high pressure Discharge Fitting and any fixed
connection or rigid piping at the machine. This is a protective measure to reduce vibration in the machines
coolant plumbing. A Pulsation Dampening Assembly is available to further minimize any adverse effects
caused by high pressure pulsations.
If the machines coolant hoses are not rated for a minimum working pressure of 1250 psi (90 Bar) (8.6 MPa)
they should be replaced. Select hose which meets the pressure requirements of the system (1250 psi mini-
mum working pressure). Recommended discharge hose size is 3/4 (19mm) I.D. Line size should not be
smaller than 1/2 (12.7 mm) I.D. Consult the factory for use of smaller discharge line sizes.
The Discharge Fitting is a 3/4 (-12) 37
o
, J IC male hydraulic fitting.
CAUTION: Never install shutoff valves in the bypass line or between the pump and Regulating Valve.
!
WARNING
This machine is equipped with a
High Pressure Coolant System.
DO NOT operate without proper
guards in place.
Read and understand Cool Jet
instruction manual before use.
Improper use may cause bodily
Pressure Regulating Valve
Install the Bypass Pressure Regulating Valve
and Discharge Tee Fitting on the Coolant
Outlet Fitting from the pump (see diagram).
As shown, theBypass Regulating Valve should
be oriented to the side opposite the Oil Level
Site Gauge.
CAUTION: Never connect a high pressure
hose directly to the Pump Discharge Fitting
without the Discharge Tee Fitting and the
Bypass Pressure Regulating Valve.
Install the Discharge Pressure Gauge in the
tapped port of the Discharge Tee Fitting. In-
stall the 1/4 NPT plug in the unused port of the
Discharge Tee Fitting. Use pipe sealant on the
gauge and plug threads.
Route the Bypass Hose to the coolant tank, as
far as possible from theSupply Pump inlet (to
reduce the chance of turbulence and cavitation).
TheBypass Hose should be secured at the cool-
ant tank end to prevent the hose from being
ejected from the tank.
TOP VIEW
Coolant
Outlet
Fitting
Pressure
(return to sump)
Bypass Hose
Bypass Pressure
Regulating Valve
Fitting
Discharge
Plug
A Properly Rated High
Pressure Discharge Hose
Discharge
Gauge
Pressure
J IC Discharge
Fitting
Tee
Adjusting
Bolt
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
9
I nst al l i ng The Cool Jet Syst em
Electrical I nstallation
Caution: This procedure should be performed by a qualified electrical technician.
WARNING! BE SURE THE POWER SUPPLY IS SWITCHED OFF BEFORE WORKING ON UNIT
Important DUTY CYCLE note: Before installing the CoolJ et system, consideration should be given
to the Start/Stop control method for the pump motor. Rapid on/off cycling of the motor can cause
premature damage and failure of the motor or contactor due to excess heat generation. If the customers
Duty Cycle requires Start/Stop of the CoolJ et more frequently than 4 times per minute, then CoolJ et
Systems requires an alternate control method to start the Cool J et pump motor with one control signal
and use another signal to a high pressure bypass valve for controlling high pressure to your machine.
POWER CONNECTION
The CoolJ et unit is shipped from the factory wired for Low Voltage operation (60HZ 208-230 / 50HZ
190). If the operating voltage needs to be changed, the electrical controller would require some modi-
fications. Motor rotational direction is optional. The CoolJ et pump performance is identical for either
rotational direction. The unit must be properly grounded.
For reference: the motor connection configurations are shown below for a Low Voltage (standard) or
High Voltage connection.
9
3
8
2
7
1 1 3
Low-Voltage (208-230)
LINE
LINE
6 5 4
7
8
9
6
5 4
High-Voltage (440-480)
2
Three Phase
ELECTRICAL CONFIGURATION AND CONTROL CONNECTION
The electrical installation will include the following steps:
A. Install the proper Control Relays for your machine and installation type
B. Install and connect the machine-side receptacles
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
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Important Duty Cycle Note: Before installing the CoolJet system, consideration should
be given to the Start/Stop control method for the pump motor. Rapid on/off cycling of the
motor can cause premature damage and failure of the motor and / or contactor due to
excess heat generation.
If short high pressure cycles are required (i.e., several starts and stops within a few minute time span), then
it may be preferred to start the CoolJet pump motor with one control signal and use another signal to a
high pressure bypass valve for controlling high pressure to your machine.
Warning: Connect only the power specified on the data label nameplate located in the
CoolJet Electrical Control Cabinet.
WARNING!
BE SURE THE POWER SUPPLY IS SWITCHED OFF
BEFORE WORKING ON UNIT
Caution: This procedure should be performed by a qualified electrical technician.
MACHINE SIDE RECEPTACLE (#4405)
The standard CoolJet includes a DIN-connector interface and mating machine-side receptacles.
This interface makes future disconnect/reconnect very convenient and allows for easy movement of
the CoolJet between machines.
Refer to the supplied CoolJet interface diagram for machine wiring instructions.
Leave CoolJet receptacle unplugged or turned off during installation and setup.
I nst al l i ng The Cool Jet Syst em
Electrical I nstallation
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
11
I nst al l i ng The Cool Jet Syst em
Electrical I nstallation
Install interface relays, RL1 and RL2 (for optional High/Low Pressure)
The Standard CoolJet includes both 24vdc and 100-120vac relays. Verify your machines output signal
voltages and install the proper relays in the CoolJet electrical panel.
Checking the Transfer Pump rotation - (to be performed by Qualified Electrical Service personnel)
1. Momentarily toggle the Fill switch on the CoolJet control panel. Verify pump fan rotation matches the
rotation arrow on the pump.
Transfer pump motor must be checked for proper rotation. Failure to comply may
damage the pump and void the warranty. DO NOT RUN DRY.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
12
Prior to I nitial Startup
Review the electrical installation instructions in the appendix.
Verify that a Filter Element has been installed into the Filter Vessel.
Insert the o-ring and wire filter hold-down into the Filter Vessel, ensuring they have seated
properly, then tighten down securely the Filter Vessel lids.
Ensure that all hose fittings are tight.
Ensure the oil level in the pump reservoir is within the acceptable range as viewed on the Oil
Level Site Glass.
I nst al l i ng The Cool Jet Syst em - SF Model s
Disconnect
Switch
Cool J et ON
Indicator Light
Air Purge Valve
Differential
Pressure Switch
Filter Drain Valve
Bypass Hose
Filter Drain Hose
(return to sump)
(return to sump)
Cool J et
Controller
Filter Inlet
Filter Outlet
Gauge
Air Purge Valve
Air Purge/Drain Hose
Gauge
Rear
View
S i d e
View
Wire Filter
Hold Down
PROCEDURE FOR PURGING AIR FROM FILTER CANISTER
1. Open Air Purge Valve, located at the top backside of the filter canister.
2. Filter Drain Valve should be closed - center spoke of the yellow handle should be vertical.
3. Turn Cool Jet Controller Disconnect Switch to the ON position. Turn the Run / Reset / Fill Switch
to the FILL position and hold the switch in this position. Only the supply pump should be running at this
time.
4. Watch the clear Air Purge/Drain Hose until only coolant is being discharged. Release the Run / Reset /
Fill Switch and Close the Air Purge Valve. Any air in the canister should have been displaced by coolant
at this point. Check the entire system for signs of leakage.
NOTE: Pressure gauge pointer should be steady. A bouncing or fluctuating pointer may indicate an excessive
amount of air is entrained in the coolant supply to the Cool J et. Opening the filters Air Purge Valve while
running may help.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
13
Prior to I nitial Startup
Review the electrical installation instructions in the appendix.
Verify that Filter Elements have been installed into the Filter Vessels.
Insert the o-ring and wire filter hold-down into the Filter Vessel, ensuring they have seated
properly, then tighten down securely the Filter Vessel lids.
Ensure that all hose fittings are tight.
Ensure the oil level in the pump reservoir is within the acceptable range as viewed on the Oil
Level Site Glass.
I nst al l i ng The Cool Jet Syst em- DF Model s
PROCEDURE FOR PURGING AIR FROM FILTER CANISTERS
1. Open Air Purge Valves, located at the top backside of both canisters.
2. Position Filter Inlet Selector Valve (yellow handle) at a 45 angle, allowing coolant flow into both filter
canisters. Position Filter Outlet Selector Valve vertically. Filter Drain Valves should be closed - center
spoke of the yellow handle should be vertical.
3. Turn Cool Jet Controller Disconnect Switch to the ON position. Turn the Run / Reset / Fill Switch
to the FILL position and hold the switch in this position. Only the supply pump should be running at this
time.
4. Watch the clear Air Purge/Drain Hoses until only coolant is being discharged. Release the Run / Reset
/ Fill Switch and Close both Air Purge Valves. Any air in the canisters should have been displaced by
coolant at this point. Check the entire system for signs of leakage.
5. Position both the Filter Inlet and Outlet Selector Valves (yellow handles), either vertically or horizontally
to operate either the right or left filter, respectively.
NOTE: Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an exces-
sive amount of air is entrained in the coolant supply to the Cool J et. Opening the active filters Air Purge
Valve while running may help.
NOTE: With both canisters completely purged of air, Filter Selector Valves can be switched while the Cool
J et and supply pump are running without affecting pump or machine operation.
Disconnect
Switch
Cool J et ON
Indicator Light
Air Purge Valve
Differential
Pressure Switch
Filter Drain Valves
Bypass Hose
Filter Drain Hose
(return to sump)
(return to sump)
Cool J et
Controller
Filter Inlet
Gauges
Filter Outlet
Gauges
Air Purge Valves
Filter Inlet Selector Valve
Filter Outlet Selector Valve
Air Purge/Drain Hose
Air Purge/Drain Hose
Side View Rear View
Wire Filter
Hold Down
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
14
START-UP PROCEDURE
1. Verify coolant level in machine reservoir is at least 3/4 full.
2. Turn on power to both the supply pump and the Cool J et pump.
3. A fully primed system will run smoothly and deliver steady flow. Check the inlet pressure. Inlet pres-
sure must not exceed 60 psi . If necessary, add a #2503 Inlet Pressure Reducing Valve.
4. Listen for any erratic noise; look for unsteady flow.
5. If the system has an air lock in the high pressure lines, the pump may fail to prime. Follow the instruc-
tions for Setting Pressure below to remove air that may be trapped in the pump manifold and high
pressure lines.
Syst em St ar t up
In the event you wish to run a pressure lower than 1000psi (70 Bar), follow the above steps to set the desired
pressure level. It is impotant to understand that the optimum orifice size will increase for a lower system
pressure.
If system pressure or flow seems inadequate, verify CoolJ et performance by installation of calibrating orifice.
Note: The Discharge Pressure Gauge needle should steadily increase. If the gauge needle stops moving while
the Adjustment Nut is being turned, this indicates a problem. Typically, this occurs when the minimum dis-
charge orifice or nozzle in the system is larger than .097 (2.46mm), or cumulative discharge orifice area
exceeds .0074 in
2
(4.767mm
2
).
The Pressure Regulating Valve is the system safety valve to prevent over-pressurization. Under no
circumstances should the setting be higher than 1000 PSI (70 Bar).
Setting Pressure / Pressure Calibration Procedure
Caution: The Cool Jet unit should not be run in production with the Calibrating Orifice installed; flow
will be over-restricted, and bypass to the coolant reservoir.
To Check the Regulator Set Point:
1. Verify that the Cool J et Disconnect Switch and
machine M code activation signal are OFF.
2. Remove the Discharge Hose Fitting from theDis-
charge Tee Fitting. Install the Calibrating Ori-
fice supplied with your system (see Illustration).
Reinstall the Discharge Hose Fitting.
3. Loosen the lockdown nut on the Pressure Adjust-
ing Nut.
4. Turn the Pressure Adjusting Nut to the full coun-
terclockwise position (3-4 turns) to decrease the
spring tension. Do not remove the bolt.
5. Activate the Cool J et System. Slowly turn the
Pressure Adjusting Nut clockwise to increase the
setting until the desired pressure is reached. Do
not exceed 1000 PSI (70 Bar) under any circum-
stance! If the system does not run smoothly, prime
by turning the Pressure Adjusting Nut in and out
a few times as it smooths out.
6. After adjusting the Pressure Regulating Valve,
tighten the Lockdown Nut to secure setting.
7. De-activate the system and remove the Calibrat-
ing Orifice. Store for later use.
Decrease
Pressure
Increase
Pressure
Regulating Valve
Adjustment
Discharge
Pressure Gauge
Pressure
Adjusting Nut
(return to sump)
Bypass Hose
Plug
Discharge Tee
Fitting
Discharge
Hose
Fitting
Calibrating
Orifice
Bypass Pressure
Regulating Valve
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
15
Cool J et Cont r ol l er and Syst em I ndi c at or s
MAIN POWER DISCONNECT
CAUTION: Three Phase line voltage may
be live at the terminal strip while the Cool Jet
Disconnect is in the OFF position.
THERMAL ALARM Indicator Lamp
Indicates that the Thermal Overload for the
Cool J et motor assembly has tripped.
Possible causes:
Amperage setting of motor starter too low.
Coolant pressure set too high.
Unbalance or problem with incoming power.
Overstress of the motor due to short cycle start/
stop.
Faulty motor.
Short circuit or faulty motor starter.
Action:
Press RESET Button
Wait 3 minutes and reset breaker inside Cool
J et controller enclosure.
Verify amperage setting and Coolant pressure.
Verify incoming line voltage.
If Alarm re-occurs, contact Cool J et Customer
Service at (714) 577-9262 for assistance.
RESET / FILL Switch
This button resets all alarm conditions. After verify-
ing any alarm cause, TOGGLE this button to silence
the BEEPER and to reset the CoolJ et controller to
ready mode.
ALARM Beeper
The Beeper indicates a CoolJ et alarm condition. See
the Indicator Lamps to identify the associated alarm.
Push RESET SWITCH to silence Beeper.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
16
Pressure & Orifice Sizing
The Cool Jet increases your machine tool's coolant pressure capability through the use of a positive displacement pump.
The pump does not create pressure, it simply pumps a constant discharge volume. Coolant pressure is controlled by
restricting the discharge line. This restriction can be the orifice in your tool or coolant nozzle. As the restricting orifice
becomes smaller in size, the system pressure increases up to the safety limit of 1000 PSI (70 bar) as set by the Pressure
Regulating Valve.
The performance benefits from high pressure assisted machining are achieved by maximizing coolant delivery into the
cutting zone.The maximum coolant velocity, pressure, and flow rate of the pump is achieved with a single orifice diameter
of approximately .097" (2.46 mm) or a cumulative discharge orifice area of .0074 in
2
(4.767 mm
2
). For restrictions
smaller than .097", excess volume is proportionally bypassed to the coolant reservoir which reduces coolant flow
through the tool or coolant nozzle.The orifice area is calculated as follows
The orifice data is based on water flowing through sharp round orifices. In actual practice, longer orifices common to
coolant fed tooling, or higher viscosity fluids such as cutting oil will result in reduced nozzle efficiency, thus decreasing
the flow through the nozzle or tool.
Understanding Pressure, Flow, and Nozzle Sizes
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
17
Air Purge Valve
Drain Valve
Assembly
Output
Gauge
Inlet
Gauge
Clean Out
Plug
Safety
Strainer
Gauge
Oil Drain Cap
Fitting
Removable
Access
Panels
Bypass Pressure
Regulating Valve
Discharge
Front View Rear View
Inlet from
Supply Pump
Differential
Pressure Switch
Electrical
Controller
Filter
Drain Hose
Air Purge/Drain Hose
Filter Drain
ValveHandle
(Yellow)
Wire Filter
Hold Down
System Notes: Filter replacement is required when the differential pressure across the filter element reaches
10-14 psi/d (1.0 Bar). The Cool J et Service Filter audible alarm will sound.
Note: A damaged or improperly installed filter element will clog the Safety Strainer Screen and cause differ-
ential pressure between the Output Gauge on the filter canister and the Safety Strainer Gauge. If this occurs
remove the Clean Out Plug from theSafety Strainer, clean the screen and reassemble.
Filter Replacement I nstructions
1. OBSERVE SAFETY SHOP PROCEDURES.
TURN MACHINE POWER OFF.
2. Open Drain Valve. Open Air Purge Valve.
3. After pressure is relieved from filter housing (Inlet
and Outlet Gauges should read zero), remove lid.
CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE
WARNI NG !
Relieve Pressure in accordance
with Manufacturers instructions
before opening Filter Vessel.
F FF FFAI L AI L AI L AI L AI LURE URE URE URE URE T TT TTO DO SO MA O DO SO MA O DO SO MA O DO SO MA O DO SO MAY RESUL Y RESUL Y RESUL Y RESUL Y RESULT TT TT
I N SERI OUS BODI L I N SERI OUS BODI L I N SERI OUS BODI L I N SERI OUS BODI L I N SERI OUS BODI LY I NJ UR Y I NJ UR Y I NJ UR Y I NJ UR Y I NJ URY YY YY. .. ..
4. Allow coolant to drain through filter element and back to machine sump. A filter canister holds 9
gallons(33.75liters). Avoid spillage; check sump level prior to draining canister.
5. Remove filter canister o-ring and wire filter hold down. Wipe inside of housing above filter element.
Remove and discard dirty filter element. Verify metal strainer basket is seated properly. Insert new element
into basket. Be sure element seal ring is properly seated all the way down into its counterbore). A snug,
light press fit prevents dirty coolant from leaking around the filter element seal ring. Install filter canister
o-ring, filter hold down and secure filter lid.
6. Close the Filter Drain Valve - center spoke of the yellow handle should be vertical.
7. If required, remove Clean Out Plug from Safety Strainer, clean screen and reassemble.
8. Before running Cool J et Pump, purge air from filter housing:
A) Leave Air Purge Valve Open. Using the FILL Switch, start the Low Pressure pump.
B) Watch the clear Air Purge Hose until only coolant is being discharged. Close the Air Purge Valve.
Release the FILL switch.
C) With Supply Pump and Cool Jet running, the filter Inlet Gauge should read between 20-60psi (1.4- 4.1Bar).
Note: Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an excessive
amount of air is entrained in the coolant supply to the Cool J et Pump.
Fi l t er Repl ac ement - (SF Model s)
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
18
Fi l t er Repl ac ement - (DF Model s)
Air Purge Valve
Filter Drain
Air Purge Valve
Filter Inlet Selector Valve
Filter Outlet
Air Purge/Drain Hose Air Purge/Drain Hose
Selector Valve
Filter Selector
Valve Handles
Output
Gauge
Output
Gauge
Inlet
Gauge
Inlet
Gauge
Air Purge Valves (backside)
Clean Out
Plug
Safety
Strainer
Gauge
Inlet from
Supply Pump
Electrical
Controller
Drain Valve
Assemblies
Filter
ValveHandles
(Yellow)
(Green)
Front View Rear View
System Notes: Filter replacement is required when the differential pressure across the filter element reaches 10-14 psi/d
(1.0 Bar). The Cool J et Service Filter audible alarm will sound. By maintaining proper filter maintenance sequencing,
changing the filter element can be accomplished without any machine down time. With the inactive filter ready (i.e. new
element properly installed and canister full of coolant), the Filter Inlet and Outlet Selector Valves can be changed at
anytime without alarm, allowing for machine operation during filter change.
Note: A damaged or improperly installed filter element will clog the Safety Strainer Screen and cause differential pressure
between the Output Gauge on the filter canister and the Safety Strainer Gauge. If this occures remove the Clean Out
Plug from theSafety Strainer, clean the screen and reassemble.
WARNI NG !
CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE CONTENTS UNDER PRESSURE
Relieve Pressure in accordance
with Manufacturers instructions
before opening Filter Vessel.
F FF FFAI L AI L AI L AI L AI LURE URE URE URE URE T TT TTO DO SO MA O DO SO MA O DO SO MA O DO SO MA O DO SO MAY YY YY
RESUL RESUL RESUL RESUL RESULT TT TT I N SERI OUS BODI L I N SERI OUS BODI L I N SERI OUS BODI L I N SERI OUS BODI L I N SERI OUS BODI LY I NJ UR Y I NJ UR Y I NJ UR Y I NJ UR Y I NJ URY YY YY. .. ..
To ready the inactive filter during a machining
cycle, the procedure is as follows:
3. Allow coolant to drain through filter element and back to machine sump. A filter canister holds 9 gallons(33.75liters). Avoid
spillage; check sump level prior to draining canister(s).
4. Remove filter canister o-ring and wire filter hold down. Remove and discard dirty filter element. Verify metal strainer basket is seated
properly. Insert new element into basket. Be sure element seal ring is properly seated all the way down into its counterbore (see filter
cut away view page 22). A snug, light press fit prevents dirty coolant from leaking around the filter element seal ring. Install filter
canister o-ring, filter hold down and secure filter lid.
5. Close the Filter Drain Valve - center spoke of the yellow handle should be vertical. Leave the Air Purge Valve open.
6. Position the Filter Inlet Selector Valve at roughly a 45 angle; redirecting some coolant flow into the inactive filter.
7. Watch the Filter Inlet Gauge on the active filter (if the inlet pressure is reduced too much , the pressure switch will activate the
Service Filter Alarm.) Adjust the position of the Filter Inlet Selector Valve to regulate flow without activating alarm.
8. Watch the inactive filters clear Air Purge/Drain Hose until only coolant is being discharged. Close the Air Purge Valve.
9. Reposition the Filter Inlet Selector Valve to its original position. The position of the Filter Outlet Selector Valve should be the same as
that of the Filter Inlet Selector Valve.
Having completed the steps outlined above, the inactive filter is ready for use, and can be switched with the Cool J et operating, without
affecting pump or machine operation.
Note: Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an excessive amount of air is entrained
in the coolant supply to the Cool J et Pump.
1. Open Drain Valve. Open Air Purge Valve.
2. After pressure is relieved from filter housing (Inlet and Outlet
Gauges should read zero), remove lid.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
19
Strainer
Basket
Filter
Element
Filter
Vessel
C
D
E
Lid O-Ring
Element Hold-down
Lid
A B
F
(Seal Ring)
Filter R Filter R Filter R Filter R Filter Remo emo emo emo emov vv vval & R al & R al & R al & R al & Re ee eeplacement placement placement placement placement
1. Install Strainer Basket (A) into Filter Vessel (F).
2. Install Filter Element (B) into Strainer Basket (A). Assure the Seal Ring at the top of the
Filter Element (B) is completely seated into the Filter Vessel (F) flange counterbore, as
shown in the cut-away drawing.
3. Install Element Hold-down (C) as shown.
4. Wipe chips and dirt from Lid O-Ring (D) and install it into the top flange of the Filter
Vessel (F).
5. Install Lid (E) and retain with the Filter Clamp Assembly (not shown).
Mai nt ai ni ng The Cool Jet Syst em
Seal Ring of the Filter Element
< Flow
Filter
Vessel
Filter
Element
Replacement Filter Elements: Ordering Information
Part No. Description
Type of
Filter
Surface
Area
2159 5 micron
1088 10 micron
1089 25 micron
1090 100 micron
Bag Element
4.4 ft
2

(0.4 m
2
)

S
t
r
a
i
n
e
r
B
a
s
k
e
t
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
20
Mai nt ai ni ng t he Cool Jet Syst em
DAI LY CHECKS
Check the filter inlet pressure gauge. The CoolJ et has a system inlet pressure rating of 60 psi (4.1 Bar)
maximum. A higher inlet coolant supply pressure must be regulated to ensure the safe operation of the Cool
J et.
Oil Drain Cap
Oil Level
Oil Level
J IC Discharge
Discharge
Pressure Gauge
Filter Drain Hose
(return to sump)
Drain Valve
(return to sump)
Bypass Hose
Bypass Fitting
Fitting
Site Glass
Fill Line
Removable
Access
Panel
Pressure
Adjusting Bolt
Bypass Pressure
Regulating Valve
Maximum Oil Level
Minimum Oil Level
Oil Drain Cap
(78)
Check the oil level and the condition of the oil. An oil level site glass has been mounted to the
enclosure permitting a quick visual verification of the condition and oil level. An acceptable oil level
is between the two indicator lines on the oil level site glass.
CAUTION: If you are losing oil from the pump reservoir, but dont see any external leakage, or if the oil
becomes discolored and contaminated, one of the diaphragms (20) may be damaged. Do not operate the
pump with a damaged diaphragm. Refer to Pump Repair: Fluid End for diaphragm service.
CAUTION: Do not leave contaminated oil in the pump housing or leave the housing empty. Remove
contaminated oil as soon as discovered, and replace it with clean oil.
PERI ODI C CHECKS
Visually check the condition of the components in the high pressure coolant circuit. Any worn or damaged
hoses should be replaced. Any leaking fittings should be tightened or replaced. Worn or damaged coolant
nozzles can result in reduced system pressure.
Periodically inspect the discharge pressure gauge to verify that the CoolJ et is operating at the desired pres-
sure. Do not adjust the Pressure Regulating Valve without a proper orifice restriction (.097 max.) at the
coolant outlet in your system. If required, use the 70-30 Calibrating Orifice and follow the pressure setting
instructions.
CAUTION: Never tighten down the pressure adjusting nut on the Regulating Valve without a proper
line restriction. This can result in an excessive pressure setting and damage your pumping system or
machine. System warranty may also be voided.
Change the oil after the first 50-100 hours of operation and every 500 operating hours thereafter. When
changing, remove the oil drain cap (78) located on the side of the pump enclosure under the oil level site
glass allowing all the oil and accumulated sediment to drain out.
CAUTION: Do not turn the pump shaft (or motor fan) while the pump oil reservoir is empty. This
may cause the need to disassemble the Pump Manifold (6) and Valve Plate (16) in order to prime the
hydraulic cells in the Hydraulic End.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
21
Pump Oil Maintenance: Check Level Daily
Check the oil level and the condition of the oil. The oil level should be 1 in. from the top of the fill
port or to the line on the oil fill plugs dipstick. For added convenience, an oil level site glass has been
mounted to the enclosure permitting a quick visual verification of the condition and oil level. An
acceptable oil level is between the two indicator lines on the oil level site glass.
CAUTION: If you are losing oil from the pump reservoir, but dont see any external leakage, or if the oil
becomes discolored and contaminated, one of the pump diaphragms may be damaged. Do not operate the
pump with a damaged diaphragm. Consult CoolJ et Service.
Pump Oil Draining - See CAUTI ON Note
Change the oil after the first 50 hours of operation and every 500 operating hours thereafter. Place the drain
pan (provided) under the oil level site glass, under the Oil Drain Cap. Remove the drain cap and allow oil
and accumulated sediment to completely drain before replacing. When finished, secure the oil drain cap.
Inspect the drained oil. Discolored oil or metal shavings in the oil may indicate the need for service of the
wet end (valves and diaphragms) or hydraulic end (plungers, pistons, camshaft assembly) of the pump.
CAUTION: Do not drain the oil and leave the reservoir empty and do not turn the pump shaft (or
motor fan) while the pump oil reservoir is empty. This may cause the need to disassemble the Pump
Manifold and Valve Plate in order to prime the hydraulic cells in the Hydraulic End. Consult CoolJ et Ser-
vice for details.
Pump Oil Replacement
Using the oil funnel provided with the CoolJ et, insert the flexible extension down into the pumps oil fill
port. Refill the pump with approximately 35 ounces of 15w-50 full synthetic motor oil. The oil level should
be to the fill line on the oil fill cap dipstick between the indicator lines on the oil level site glass, or approxi-
mately 1 (25mm) from the top of the oil fill port.
Changing The Pump Oil
Mai nt ai ni ng The Cool Jet Syst em
Maximum Oil Level
Oil Drain Cap
Minimum Oil Level
Change Oil Every
500 hours
Refill With
Mobile One
(15W-50)
Full Synthetic
Motor Oil
or equivalent
Capacity
35 ounces
(1.03 Liters)
O
i
l
Access Hole
Pry cap off
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
22
Tr oubl eshoot i ng Al ar ms
Under normal operation, the CoolJet High Pressure System will be activated by the High Pressure m-
code or the Manual control switch at the machine control. The CoolJet system will start and stop the
high pressure and low pressure pumps as needed.
If the CoolJet System does not start, verify that the Electrical harness is properly connected and the
CoolJet Disconnect Switch is in the ON position. Also verify RESET - RUN- FILL switch in RUN
position.
In the event of a CoolJet alarm, the CoolJet Alarm Beeper will sound.
Refer to the chart below for alarm indications.
Coolant Alarm - Low Coolant or Filter * Turn OFF the coolant command.
(Alarm Beeper only) Toggle RESET switch to silence Beeper.
Possible Causes Resolution
Machine tool coolant level too low Verify and add coolant
Air or turbulence at the feeder pump inlet Reposition return lines to sump
Sump pump clogged with debris Remove debris/clean sump
Cool Jet filter dirty Replace filter element
Filter Drain Valve open Close Filter Drain Valve
Cool Jet Safety Strainer clogged Clean Strainer
Faulty Pressure Switch (#0371) Consult Cool Jet service
Faulty Differential Pressure Switch (#2273) Consult Cool Jet service
Cool J et service at (714) 577-9262 x111
______________________________________________________________________________
Thermal Alarm - * Turn OFF the coolant command.
(Alarm Beeper and Thermal Overload Lamp) Toggle RESET switch to silence Beeper.
Possible Causes Resolution
Breaker tripped Reset Breaker inside Cool Jet controller
Incorrect amperage setting of Breaker Verify amperage settings per Appendix
Unbalance or problem with incoming power. Verify incoming line voltage per nameplate.
Coolant pressure too high (1000psi maximum) Check pressure / Re-calibrate pressure
Short circuit or faulty motor starter Consult Cool Jet service at (714) 577-9262 x111
Cool Jet motor faulty Consult Cool Jet service
Motor stress due to short cycle start/stop. Consult Cool Jet service
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
23
If your pump is not performing properly, it will usually cause a change in coolant delivery at the
tool or coolant nozzle (drop in pressure, pulsations, rough running, etc.). The most common
causes of pumping problems can usually be found in the inlet lines to the pump. A clogged
filter, low coolant tank levels, and air being drawn into the system through loose inlet fittings
prevent adequate supply to the pump inlet and can cause cavitation. Cavitation will cause a drop
in pumping performance; prolonged cavitation can damage the pump. The symptoms and typical
causes of cavitation are listed below:
Drop in Volume or Pressure
Cracked inlet hose
Low coolant level in machine
Excessive aeration and turbulence in coolant tank
Coolant nozzle(s) have worn oversize
Pressure Regulating Valve bypassing fluid to tank
Worn pump valve parts
Foreign material in pump inlet or outlet valves
Loss of oil prime in cells because of low oil level
Ruptured diaphragm
Warped manifold from overpressurized system
Pump O-rings forced out of their grooves from
overpressurization
Cracked cylinder housing
Pulsating High Pressure
Foreign object lodged in pump valve
Loss of prime in hydraulic cells because of low oil level
in pump oil reservoir
Air in suction line
Valve spring broken
Aeration or turbulence in coolant tank
Pump Runs Rough
Worn pump valves
Air lock in high pressure discharge lines
Pump oil level low
Air in inlet hose
Restriction in inlet line
Hydraulic cells not primed after changing
diaphragms
Foreign material in inlet or outlet valves
Damaged diaphragm
Fatigued or broken valve spring
Broken piston return spring
Coolant in Pump Oil Reservoir
Ruptured diaphragm
Hydraulic cells not properly primed after
diaphragm replacement
Diaphragm screw O-ring missing or cracked
Cracked cylinder housing
Loss of Oil from Pump Reservoir
External seepage
Rupture of diaphragm
Diaphragm screw O-ring missing or cracked
Worn shaft seals
Oil drain cap or fill cap loose
Valve plate and manifold bolts loose
If you are experiencing pumping problems, the first step is to eliminate the possible problems regarding fluid supply
to the 70-30 pump inlet. Some of the problem symptoms and possible causes are listed below:
Symptoms of Cavitation
Excessive pump valve noise
Premature failure of spring or retainer
Premature failure of diaphragms
Volume or pressure drop
Rough-running pump
Piston return spring failure (inside hydraulic end)
Some Causes of Cavitation
- Inlet line collapsed or clogged
- Clogged line strainer or filter
- Inlet hose too small or too long
- Air leak in inlet line
- Too many valves and elbows in inlet line
- Air entrained in fluid piping system
- Aeration and turbulence in supply tank
Tr oubl eshoot i ng t he 70-30 Pump
General Rule of Thumb: If the problems remain, the 70-30 pump assembly may require
service. With a few exceptions, the following rule of thumb regarding pump service will apply:
1. Pumping problems accompanied by fluctuating/fluttering discharge pressure gauge needle
generally requires service of the Fluid End (Valves and/or Diaphragms).
2. Problems accompanied by low pressure output with a steady gauge needle generally requires
service of the Hydraulic End.
If you are going to service the 70-30 pump assembly, you may require a 70-30 Tool Kit available
from your CoolJ et distributor. If you need assistance, contact CoolJ et Customer Service.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
24
Pump Repai r : Fl ui d End
Servicing the Valves and Diaphragms
NOTE: It is recommended that you purchase the CoolJet 70-30 Tool Kit (#0975) prior to working on the pump.
This section explains how to disassemble and inspect all easily-serviceable parts of the pump. Repair procedures for
the hydraulic end (oil reservoir) of the pump, are included elsewhere in this manual. This fluid end service may be
performed with the pump head either attached to the motor or removed.
CAUTION: Dont disassemble the pump unless you are a skilled mechanic. For assistance, contact CoolJet Systems.
CAUTION: The two bolts (25, 29) that screw through the back of the housing into the cylinder casting hold the
casting over the hydraulic end of the pump. Do not remove them except when repairing the hydraulic end.
1) Removing Manifold and Valve Plate
a) Remove all nuts (31) and bolts (4) around the mani-
fold. Do not remove the two bolts (25, 29) that are
installed through the back of the pump housing.
b) Use a 3/8 in. hex Allen wrench to remove the
centerbolt (1) and its washer (2) in the center of the
manifold.
CAUTION: Do not turn the pump drive
shaft (or motor fan shaft if the pump is at-
tached) while the manifold (6) and valve
plate (16) are removed from the pump, ex-
cept when removing diaphragms or
repriming the hydraulic cells.
c) Remove the manifold (6).
d) Remove the two screws (23) and valve plate (16).
e) Inspect the manifold for warpage or wear around
the inlet and outlet ports. If wear is excessive, re-
place the manifold, or return it to CoolJ et for service.
To check if the manifold is warped, remove the O-
rings and place a straightedge across it. A warped
manifold should be replaced.
f) Inspect the valve plate in the same manner as the
manifold.
2) Inspect Valves (10-15)
The three inlet and three outlet valve assemblies are
identical (but face in opposite directions). Inspect each
valve as follows:
a) Check the spring retainer (15), and replace if worn.
Remove the tetra seal (flat O-ring, 14).
b) Check the valve spring (13). If it is shorter than a
new spring, replace it (dont just stretch the old spring).
c) Check the valve poppet (12). If worn excessively,
replace it.
d) Remove the valve seat (11). A seat remover is
included in the 70-30 Tool Kit. Be careful not the
break the metal ridge around the O-ring groove. In-
spect the valve seat for wear, and replace it if worn.
The seat has a chamfer on the I.D. edge which con-
tacts the valve poppet (12). If the seat is worn, it should
be replaced; do not reuse it.
Do Not
Remove
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
25
Pump Repai r : Fl ui d End
Servicing the Valves and Diaphragms
Valve Wear: Causes
Normal wear over time.
Cavitation.
Abrasive matter in the coolant.
Valve incompatible with corrosives in the fluid.
Valve Spring / Retainer Failure: Causes
Cavitation.
Foreign object in the pump.
Spring/Retainer material incompatible with pumped fluid.
Excessive (200 psi+) inlet pressure.
Installing Outlet Valves on Valve Plate
Correct
Incorrect:
Retainer leg
pointing toward
3) Reinstall The Valve Assemblies:
a) Clean the valve ports and shoulders with emery cloth;
lubricate them with lubricating gel or petroleum jelly.
b) Install the O-ring (10) on the valve seat (11).
c) Inlet Valves (3 center valves). Insert the spring retainer
(15) into the valve plate, then insert the spring, valve and
valve seat (11, 12, 13). The tetra seal (14) goes between the
retainer and seat.
d) Outlet (3 outer valves). Insert the valve seat, valve, and
spring, then the retainer. Install the flat O-ring (14) between
the retainer and seat. Position the spring retainers (15) so a
leg does not point toward the center of the pump (refer to
the illustration).
4) Inspect and Replace Diaphragms (20):
a) Lift the diaphragm by one edge, and turn the pump shaft
until the diaphragm pulls up. This will expose machined
cross-holes in the plunger shaft behind the diaphragm.
b) Insert an Allen wrench through one of the holes, to hold
the diaphragm up. The proper size tool is included in the
70-30 Tool Kit.
c) Remove the screw (17), O-ring (18), and follower (19) in
the center of the diaphragm.
d) Remove the diaphragm, and inspect it carefully. A rup-
tured diaphragm generally indicates a pumping sys-
tem problem, and replacing only the diaphragm will
not solve the larger problem. Inspect the diaphragm
for the following:
Half-moon marks: Usually caused by cavita-
tion of the pump or excessive vacuum.
Concentric circular marks: Usually caused by
cavitation of the pump.
Small puncture: Usually caused by a sharp chip
or foreign object in the coolant.
Diaphragm pulled away: Usually caused by
overpressurization of the pump.
Slice in ridge of diaphragm: Occurs when a
diaphragm is operated at cold temperatures.
Diaphragm edge chewed away: Usually
caused by overpressurizing the system.
e) Inspect the plunger (21) for any rough surfaces or
edges. Do not remove the plunger from the plunger
shaft. Check for plunger rotation. Plunger should
not rotate on shaft. Smooth the surfaces and edges as
necessary with emery cloth or a fine file.
CAUTION: If a diaphragm has ruptured
and foreign material or water has entered
the oil reservoir, do not operate the pump.
Check all diaphragms, then flush the reser-
voir completely (as outlined below) and re-
fill it with fresh oil. Never let the pump stand
with foreign material or water in the reser-
voir, or with the reservoir empty.
f) Install new diaphragm (or reinstall the old one, as
appropriate), ridge side out.
g) Clean the screw (17) and remove any oil from it.
Apply medium-strength threadlocker to the screw.
Reinstall the screw and follower (19), and a new O-
ring (18). Tighten to 18lb-in (.20 meter-kgs).
h) Repeat the above inspection procedure (and re-
placement, if necessary) with the other two dia-
phragms.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
26
Priming the Pump Hydraulic Cells
During priming, oil and
air will come out from
behind the 3 diaphragm
edges. Continue turning
the shaft until only clean
oil comes out.
Diaphragms
Reinstalling Valve Plate
10 OClock Position
Long screw (29) in
threaded hole.
4 OClock Position
Shrot screw (25) in
threaded hole.
5) Flush Contaminate from Hydraulic End
(only if a diaphragm has ruptured)
a) Remove the oil drain hose assembly (34) and allow
all oil and contaminate to drain out.
b) Fill the reservoir with kerosene or solvent, manually
turn the pump shaft to circulate the kerosene, and drain.
c) Repeat the flushing procedure (step b).
d) Fill the reservoir with fresh oil, manually turn the
pump shaft to circulate the oil, and drain once again.
e) Refill the reservoir with oil- Mobile One (15w-50) or
equivalent. If the oil appears milky there is still contami-
nate in the reservoir. Repeat the flushing procedure until
the oil appears clean.
6) Prime the Hydraulic Cells
a) With the pump horizontal, fill the reservoir with oil-
Mobile One (15w-50) or equivalent.
b) All air in the oil within the hydraulic cell (behind the
diaphragms) must be forced out by turning the shaft (and
thus pumping the piston). A shaft rotator is included in
the 70-30 Tool Kit. Turn the shaft until a bubble-free
flow of oil comes from behind all the diaphragms. Watch
the oil level in the reservoir; if it gets too low during
priming, air will be drawn into the pistons (inside the
hydraulic end) and will cause the pump to run rough.
c) Wipe excess oil from the cylinder housing (24) and
diaphragm.
Pump Repai r : Fl ui d End
Servicing the Valves and Diaphragms
7) Reinstall Valve Plate (16) and Manifold (6)
NOTE: Use the bolt (29) protruding through the cylinder
casting at the 10 oclock position to locate the valve plate
(16) on the cylinder housing (24). Place the blind hole
in the valve plate over this bolt.
a) Reinstall the valve plate (16), with the valve assemblies
installed as outlined above, onto the cylinder housing (24).
Recheck that the blind hole is over the protruding bolt at the
10 oclock position.
b) Reinstall two capscrews (23) to secure the valve plate
(16) to the cylinder housing (24). These screws lightly se-
cure the plate to the housing to hold the diaphragms (20) in
place. Do not overtighten item (23) screws.
c) Reinstall the O-rings (7, 8, 9) on the rear side of the
manifold. Use O-ring lube or grease to hold them in place.
d) Reinstall the manifold onto the valve plate; be sure the
drain plug (3) is at the bottom of the manifold.
e) Insert all bolts (4) around the edge of the manifold, and
alternately tighten opposite bolts until all are secure. Torque
to 45 lb-ft (6.2 meter-kgs).
f) Reinstall the centerbolt (1), with its washer (2) and tighten
it. Torque to 45 lb-ft (6.2 meter-kgs).
g) Recheck all bolts for tightness.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
27
Pump Repai r : Removal & Repl ac ement
Regular maintenance of the 70-30 pump and some service can be performed with the pump head
bolted onto the motor. Replacement of the pump head and servicing of the hydraulic end generally
requires removing the pump head from the motor. Follow the procedure below for removal and
reassembly of the pump to the motor.
Note: Before proceeding, extra bolts may be required to assist in removing the pump from the
motor. These extraction bolts should be 1/2-13 thread with a minimum 3 thread length.
Pump Head Reassembly
1) Wipe the pump shaft clean and apply anti-seize
lubricant to the shaft and keyway. Place key on
the pump shaft and apply more anti-seize to the
key. The pump is now ready to be placed onto the
motor.
2) Align keyway of the motor shaft with the pump
shaft. Slide pump head onto motor.
NOTE: Assure that the key does not get pushed
all the way to the end of the key-way toward the
pump. Use a screwdriver during assembly to push
the key into the motor shaft bore.
3) Slide the pump head forward until the flange
mates with the motor mounting face.
4) Install the four bolts (38) and lockwashers (37)
to secure the pump to the motor.
NOTE: It is important while tightening these bolts
to support the weight of the pump head. This re-
duces the weight load on the motor bearings dur-
ing pump operation.
5) Alternately torque the bolts in a cross pattern
to 55ft-lb (7.60 meter-kgs).
6) Reinstall Pressure Switch Hose and Oil Drain
Hose.
7) Reinstall the Pressure Regulating Valve and
Inlet Hose assemblies (see Section III).
8) Follow the start-up instructions previously cov-
ered in this manual.
Pump Head Removal
1) Turn off main power at the machine.
2) If your system has filter canisters, drain
the coolant from them.
3) Disconnect and drain the Inlet Hose As-
sembly and Pressure Regulating Valve Assem-
bly from the CoolJ et Discharge Fitting.
4) Remove Pressure Switch hose from
CoolJ et inlet nipple.
5) Remove oil drain hose from oil drain and
cap outlet. Drain oil from Oil Site Glass, or
the pump- whichever applies.
6) Use a 3/4 wrench to remove the four 1/2-
13 bolts (38) which secure the pump mount-
ing flange to the motor face.
7) With the bolts removed, the pump head
should be free to rotate about the motor axis.
The pump head might slide freely from the
hollow motor shaft. Support the pump head
and smoothly remove it from the motor shaft.
8) If pump does not separate from motor, in-
sert two extraction bolts (1/2-13 x 3 min.
thread length) into the two threaded holes of
the pump flange. Rotate the pump head on
the motor shaft to assure that the extraction
bolts do not damage the threaded holes in the
motor mounting face.
9) In small, even increments (one revolution
max.), alternately tighten down the extraction
bolts.
NOTE: Use care to assure that the pump trav-
els straight and evenly away from the motor.
The pump shaft may bend if this is done in-
correctly.
10) The pump head will slowly separate
from the motor face. Continue tightening
the extraction bolts until the pump may be
removed freely.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
28
Pump Repai r : Hydr aul i c End
A Reassembling Tip
10 OClock Position
Long screw (29) in
threaded hole.
4 OClock Position
Short screw (25) in
threaded hole.
CAUTION: Do not disassemble the hydraulic end of the pump unless you are a skilled mechanic. For assistance,
contact CoolJet Systems.
The pump head should be removed from the motor before servicing the hydraulic end components. Follow the pump
head removal procedure covered earlier in this manual.
CAUTION: The two bolts (25, 29) that screw through the back of the housing into the cylinder casting (24) hold the
casting to the pump housing. Do not remove them except when repairing the hydraulic end.
NOTE: The following service procedures refer several times to the 70-30 Tool Kit. We strongly urge you to purchase
this tool kit before attempting to repair the hydraulic end of the pump. The tool kit is available from CoolJet Systems or
your local distributor.
1) Removing Cylinder Housing and
Shaft Assembly
a) Remove the manifold, valve plate, and dia-
phragms, as outlined in previous section.
b) Drain the oil from the pump housing by remov-
ing the oil drain hose assembly (34). Inspect oil
for contaminate or metal shavings.
c) Set the hydraulic end of the pump face-down
(shaft up) on the cylinder casting (24).
d) Check the shaft for sharp burrs. Smooth any
burrs to prevent scarring the housing seals (64)
when you disassemble the pump.
e) Remove the bolts (25, 29) which secure the
housing to the cylinder casting. The piston return
springs (50) will force the cylinder housing (24)
and pump housing (30) apart.
NOTE: When reassembling, note that one bolt
(29) is longer than the other (25). The longer
bolt must be installed in the 10 oclock position of
the housing.
f) Lift off the pump housing (30).
g) Inspect the cam and bearings (62), and the bear-
ing race in the rear of the pump housing. If the
bearings are pitted or binding, or if the housing
race is worn, contact CoolJ et Systems.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
29
Pump Repai r : Hydr aul i c End
2) Remove Piston Assemblies (59)
a) With the pump housing (30) removed, turn the cyl-
inder housing (24) over and set it on a flat surface,
piston side down.
b) With the diaphragms removed (covered earlier in
this manual), reinsert a follower screw (17) into the
hole behind the plunger (21). Tap the screw lightly
with hammer: the plunger (21) should slip off the valve
plunger. The used plunger should be discarded.
Contact CoolJ et Systems or your local distributor to
order replacement parts.
c) Repeat step b for the remaining pistons.
NOTE: When you reassemble the hydraulic piston,
use new plungers (21). They are press-fit onto the
valve plungers and are not reusable.
3) Reassemble Pump Housing (30) and Hous-
ing (24)
NOTE: Inspect the shaft seals (64) before continuing.
If they look damaged in any way, replace them (re-
move by tapping them out from inside the pump hous-
ing). Both seals should be replaced at the same time.
a) Place the cylinder housing (24) face-down on a flat
surface.
b) Insert the assembled pistons (50-59) into the cylin-
der casting. The holes on the foot end of the pistons
should all point toward the center of the casting.
c) Note the location of the outer ring of holes in the
cylinder casting and the pump housing flange (in par-
ticular, the holes where bolts (25) and (29) will be
installed. Screw threaded studs (from the 70-30 Tool
Kit) into the two threaded holes at the 10 and 4 oclock
positions of the cylinder casting.
d) Stand the camshaft assembly (62) on the cylinder
casting (24).
CAUTION: The pilot bearing MUST be properly
nested in the bearing race during assembly. If mis-
aligned, the bearing will be damaged and the pump
will fail within a few hours of operation.
e) Install the O-ring (65) and slide the housing (30)
down over the shaft and onto the threaded studs (from
step c). Be sure the holes in the housing and the cylin-
der casting are properly aligned.
f) Install washer (5) and nuts (31) on the threaded
studs, but dont tighten yet. You may want to insert
two or more bolts (4) into the unthreaded holes of the
housing and cylinder casting to help align the parts.
g) Alternately tighten the nuts (31) to evenly draw
the housing down to the cylinder casting. Be sure
the O-ring (65) stays in place.
NOTE: As you tighten the nuts, keep checking the
shaft alignment by turning the shaft (use the rota-
tor in the 70-30 Tool Kit). If the shaft begins to
bind and become difficult to turn, back off the nuts
and realign the shaft. When the housing is tight
against the cylinder casting, you should be able
to turn the shaft smoothly.
h) After the housing and casting are together, re-
move the threaded stud at the 4 oclock position
of the housing and replace it with a bolt (25) and
washer (5). Replace the threaded stud at the 10
oclock position with a bolt (29) and washer (5).
i) Turn the shaft again to check its alignment.
4) Replace Shaft Seals
a) Apply a thin film of grease on the seal protector
tool (part of the 70-30 Tool Kit). Slide both seals
onto the tool, with the spring side of the seals to-
ward the open end of the tool. Apply a heavier
coat of grease between the seals and press them
together.
b) Apply a coating of Locite High-Performance
Pipe Sealant with Teflon, or a comparable prod-
uct, to the outer surface of both seals and the in-
side surface of the opening in the pump housing
where the seals will rest.
c) Apply a light film of grease to the drive shaft.
Slide the seal protector tool (with the two seals)
over the end of the shaft.
d) Slide the seal insertion tool (from the 70-30
Tool Kit) over the seal protector tool, and press
the seals completely into place. Tap the tool with
a soft mallet to firmly seat the seals.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
30
Pump Repai r : Hydr aul i c End
5) Adjust Camshaft Endplay
a) If the three set screws (22) are in the cylinder
housing (24), remove and clean them.
b) Insert the centerbolt (1) into the hole in the center
of the cylinder casting. Turn it in to move the bear-
ing adjusting plate (61) and cup tight against the bear-
ing cone.
c) Back out the centerbolt two full turns, then turn it
back in again until it is tight against the adjusting
plate (61).
d) Back out the centerbolt exactly 1/4 of a turn.
e) With a plastic mallet (or a regular mallet or wooden
board) to prevent damage to the shaft, rap the end of
the shaft 3 or 4 times. This will provide about .006
endplay in the shaft.
f) Apply removable threadlocker to the threads of
the three cleaned set screws (22). Screw the three set
screws (22) into the cylinder casting until they con-
tact the bearing adjusting plate (61).
g) Remove the centerbolt (1).
6) Reinstall Plungers
NOTE: If the plungers (21) have been removed from
the valve plungers, do not reuse them. Install new
ones instead.
a) Place a plunger on the exposed screw end of the
plunger guide tool from the 70-30 Tool Kit. The flat
side of the plunger should face the tool.
b) Screw the guide (with the plunger) into the valve
plunger until tight.
c) Hold the single bottom handle of the guide, and
turn the double top handle to force the plunger to seat
on the valve plunger. This is a press fit when in-
stalled, the plunger should be tight against the shoul-
der of the valve plunger.
NOTE: Do not remove the plunger guide until the
diaphragm is installed.
d) Install the diaphragm as outlined below, then re-
peat the procedure for the other two plungers and
diaphragms.
7) Reinstall Diaphragms
a) With the plunger guide tool still screwed into the
valve plunger (54), pull the valve plunger up until the
cross-holes in the valve plunger are exposed.
b) Insert a diaphragm Allen wrench (from the 70-30
Tool Kit), or similar dowel-type object, through the
holes to hold the plunger (21) away from the cylin-
der casting, and to keep the valve plunger from turn-
ing when the diaphragm is being installed.
c) Place the diaphragm (20) onto the plunger (21),
ridge-side out.
d) Center the diaphragm follower (19) on the dia-
phragm.
e) Place the O-ring (18) onto the follower screw
(17).
f) Apply a small amount of threadlocker to the
threads of the follower screw.
g) Insert the follower screw (with O-ring) through
the diaphragm follower (19) and diaphragm (20),
and screw it into the valve plunger (54).
h) Hold the diaphragm Allen wrench, and tighten
the follower screw to 18 in-lbs. of torque.
i) Repeat the above procedure for the plungers and
diaphragms of the other two cylinders.
j) Fill the reservoir with fresh oil and prime the
hydraulic cells, as outlined previously.
8) Reassemble Pump Head
a) Reassemble the pump head as outlined previ-
ously.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
31
Repl ac ement Par t s
Pump Unit
94
95
100
108
113
115
116
117
118
70
88
87
83
84
82
89
80
111
81
78
79
101
112
77
90 114
Item Part # Description Qty.
70 2176 Enclosure Assembly, 70-30 SF 1
77 1011 Inlet Nipple 1
78 2186 Oil Drain Cap, 1/4 NPT 1
79 0866 Plug (3/4 NPT) 1
80 2517 Assy, Pressure Regulating Valve 1
81 2516 Valve, Regulator, 1000 psi 1
82 0032 Hose, Bypass,
5
/
8
ID x 10 1
--- 0391 37 J IC Hose Barb 1
83 2515 Adapter Fitting, Regulator 1
84 0735 Bypass Elbow 1
87 0914 Calibrating Orifice (70-30 Series) 1
88 0869 Discharge Tee Fitting 1
89 0870 Gauge, Back Mount, 1500 psi 1
90 0843 Outlet Nipple 1
94 2134 Pump, 8GPM @ 1000PSI 1
95 0794 Motor 6/5 HP, 60/50 Hz 1
100 0223 Baseplate, Riser Assy, 70-30 1
101 0993 Bolt, Motor Mount 4
108 0857 Foot Assy 4
Item Part # Description Qty.
111 2187 Oil Drain Hose Assembly 1
112 2182 Oil Level Site Gauge 1
113 2181 Pressure Switch Hose Assembly 1
114 2110 Pressure Switch Snubber 1
115 0371 Pressure Switch 1
116 1062 Pressure Switch Cable/din Assembly 1
117 2199 Inlet Hose, 1 ID 1
118 2197 Hose Clamp 1
--- 0975 70-30 Tool Kit (not included) --
--- 0095 Machine Warning Label 1
--- 2194 Oil Fill Funnel 1
--- 2195 Oil Drain Pan 1
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
32
Repl ac ement Par t s
Filtration Components - (SF Models)
120
121
Filter Vessel - Cut Away View
119
Item Part # Description Qty.
116 1062 Pressure Switch Cable/din Assembly 1
117 2199 Inlet Hose, 1 ID 1
119 2358 Filter Hold Down 1
120 2355 Basket, Replacement - HCF 1
121 2271 Filter Vessel, O-Ring 1
122 2341 Clamp, Clamp Assy - HCF Lid 1
123 0897 90 Elbow, 1MPT x 1 MJ IC 1
124 2205 Swivel Elbow, 1 J IC x 45 1
Item Part # Description Qty.
125 2273 Differential Press. Switch (10-14 psid) 1
126 2472 Diff. Pressure Switch Cable Assy. 1
127 2342 Screen, Strainer-60 mesh 1
128 2150 Air Purge Valve 1
130 2145 Drain Valve 1
131 2317 Drain Hose, ID x 10 1
117
125
131
130
126
127
122
128
124
123
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
33
136
124
125
126
127
130
131
136
130
128
122
128
135
117
120
121
Filter Vessel - Cut Away View
119
Repl ac ement Par t s
Filtration Components - (DF Models)
Item Part # Description Qty.
117 2199 Inlet Hose, 1 ID 1
119 2358 Filter Hold Down 2
120 2355 Basket, Replacement - HCF 2
121 2271 Filter Vessel, O-Ring 2
122 2341 Clamp, Clamp Assy - HCF Lid 2
125 2273 Differential Press. Switch (10-14 psid) 1
126 2472 Diff. Pressure Switch Cable Assy. 1
Item Part # Description Qty.
127 2342 Screen, Strainer-60 mesh 1
128 2150 Air Purge Valve 1
130 2145 Drain Valve 2
131 2317 Drain Hose, ID x 10 2
135 2306 Controller Mount 1
136 2200 Filter Selector Valve 2
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
34
Service and Repair Kits
0975 70-30 Tool Kit
2028 Fluid End Repair Kit
(includes: 7, 8, 9, 10, 11, 12, 13, 14, 15, 18, 20)
2206 Diaphram Repair Kit, V-2
(includes 7, 8, 9, 18, 20)
2030 Valve Repair Kit, Standard
(incl. 7, 8, 9, 10, 11, 12, 13, 14, 15)
2031 Valve Repair Kit, Ceramic
(incl. 7, 8, 9, 10, 11*, 12*, 13, 14, 15)
ITEM PART # DESCRIPTION QTY
1 0951 Center Bolt 1
2 0987 Washer, 1/2, Flat 1
3 0952 Priming Plug 1
4 0988 Bolt, 3-1/2, Hex Head 6
5 0989 Lockwasher, 3/8 18
6 0520 Manifold 1
7 0772 O-ring, Center Bolt 1
8 2026 O-ring, Manifold, Inner 1
9 2027 O-ring, Manifold, Outer 1
10 0991 O-ring, Valve Seat 6
11 0953 Valve Seat 6
12 0954 Valve 6
13 0955 Valve Seat 6
14 0956 Tetra Seal 6
15 0957 Valve Spring Retainer 6
16 0958 Valve Plate 6
17 0982 Screw, follower 3
18 2024 O-ring, follower 3
19 0682 Follower 3
20 2207 Diaphragm, Viton 3
21 0961 Plunger 3
22 0983 Setscrew, Adjusting Plate 3
23 0984 Soc. Hd. Cap Screw 2
24 0962 Housing, Cylinder 1
25 0994 Capscrew, 3/8 x 7/8 long 1
26 0992 O-ring, Oil fill 1
27 0963 Oil fill cap (with breather) 1
29 0985 Capscrew, 3/8-16 x 1-1/8 1
30 0964 Housing, Pump 1
31 0986 Nut, 3/8-16, Hex 6
32 2202 Elbow, #6 MJ IC x 1/8FPT 1
33 0879 Nipple, 1/8 x 4-1/2 1
37 0888 Lockwasher, 1/2 4
38 0887 Capscrew, 1/2-13 x 1-1/4 4
40 0966 Mounting Flange 1
41 0993 Capscrew, 3/8-16 x 3/4 4
42 2266 Gasket, cover 1
43 2267 Cover 1
44 0993 Screw, R.H. Mach, M4 x 12 - 4 4
45 0880 Elbow, 1/8 FPT 1
45
Repl ac ement Par t s
70-30 Pump - Fluid End
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
35
ITEM PART # DESCRIPTION QTY
21 0961 Plunger 3
24 0962 Cylinder Housing 1
59 0972 Piston Assembly 3
60 0997 O-ring, adjusting plate, viton 1
61 0973 Bearing Adjusting Plate 1
62 0974 Shaft/Cam Assembly 1
63 1184 Key, 3/16 x 1/4 x 1-3/4 1
64 0978 Seal, shaft 2
65 0979 O-ring, pump housing, viton 1
- 0975 70-30 Tool Kit -
Repl ac ement Par t s
70-30 Pump- Hydraulic End
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
36
Appendi x A: El ec t r i c al Cont r ol l er Schemat i c
21
23
T1.4
SCHEMATIC
B
1 2
FAX: (714) 5779271
2900A SATURN STREET
BREA CA 926216203
PHONE: (714) 5779262
COOL JET SYSTEMS
TERMINAL CONN.
WIRE NUMBERS
FIELD WIRING
( )
T1.2
T1.3
CR1.2
(RED)
(RED)
4
1
2
RL2
(RED)
(17)
CB1 2A
(WHITE)
(10)
(N)
(10GA BLACK)
(10GA BLACK) (T11)
(S11)
MC1
L3
L2
T3
T2
460VAC, 11 AMPS
(10GA BLACK) (R11) L1 T1
TOTAL ALARM B
PRESSURE SWITCH
DELAY TIME "5 SEC"
THERMAL TRIP
H.P. MOTOR STARTER
(18)
PL1 YELLOW
CR1
(WHITE)
T1
A1 A2
MC1
OL1
(N)
PUMP MOTOR
E
M1
COOL J ET
RL1.1
PE
CR1.3
22
T1.4
27
26
CR1.4
ALARM RESET
ALARM COMMON
TOTAL ALARM
N.C.(OPEN=ALARM)
COOLANT ALARM
N.O.(CLOSE=ALARM)
THERMAL ALARM
N.O.(CLOSE=ALARM)
12
(15)
(10)
(N)
(20)
N
(RED)
(RED)
(19)
#7030P-3557
4PDT
4PDT
CR1.1
6 HP
115 VAC
OL1
208-230VAC, 16.5 F.L.A.
M2
MC2
L2
L3 T3
T2
OL2
L1 T1
PUMP MOTOR
.75 HP
208-230VAC, 2.4 F.L.A.
E
A2 A1
MC2
OL1
OL2
(N)
CB2 2A
150 VA
Z
Reset
(MOM)
(MOM.)
RUN
Fill
208-23OVAC, 21 AMPS
BCPD
460VAC, 8.8 F.L.A.
460VAC, 1.3 F.L.A.
(24vdc or 110vac)
3
RL1 Z HPC "ON"
RL2.1 11
RL1.2
RL2.2
(WHITE)
115 VAC
CR2
2PDT
CR2.1
LP
DP
15
L.P. MOTOR STARTER
(12)
(11)
(15)
(N)
(13) (13)
J 2
CR1.4
25
THERMAL ALARM
N.C.(OPEN=ALARM)
OL2
(14)
(16)
CR2.2
10
32
30
31
29
RL2.2
RL1.2
AVAILABLE
12
AVAILABLE
11
10
9
(GRN/YEL)
(BLACK)
(BLACK)
(BLACK)
5
8
7
6
PE
#4331 POWER &
CONTROL HARNESS
1
3
2
#3106P
#3108P
#3109P
(24vdc or 110vac)
LPC "ON"
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
37
CoolJ et Customer Service may be reached in the U.S.A. at:
Telephone} (714) 577-9262 Fax} (714) 577-9271
Email} [email protected]
Please present your CoolJ et serial number, machine tool type,
and the name of your distributor when you call or email.
MKT INNOVATIONS / COOL JET WARRANTY
What Is Covered: MKT Innovations warrants that the MKT product enclosed with this Limited Warranty statement
will conform to the manufacturers specifications and be free from defects in workmanship and material for a period of
one year from the date of manufacturers shipment.
In Case of Warranty Problems: Should your MKT product prove defective during this period, you must promptly
notify your CoolJ et Distributor. If required, MKT may request that you send the product securely packaged in its
original container or an equivalent, along with proof of the date of purchase, to your CoolJ et Distributor. MKT Innova-
tions will, at its option, repair or replace on an exchange basis the defective unit, without charge for parts or labor.
Postage, insurance and shipping costs incurred in presenting your MKT product for warranty or service are the users
responsibility.
What This Warranty Does Not Cover: This warranty does not apply to defects caused by the fault or negligence of the
buyer or third party, or should the product fail to be properly maintained, or fail to function properly as a result of
misuse, improper installation, improper electrical current, improper shipping, damage caused by disasters such as fire,
flood, and lighting, to defects reported to MKT after the warranty period has expired or to the normal wear of compo-
nent parts of the product such as valves and seats, O-rings, diaphragms, springs, etc.
The warranty and remedy provided above are exclusive and in lieu of all other expressed warranties and unless stated
herein, any statements or representations by any other person or firm are void. The duration of any implied warranties
of merchantability or fitness of a particular purpose shall be limited to the duration of the express warranty set forth
above. Except as provided in this written warranty, neither MKT Innovations nor its affiliates shall be liable for any loss,
inconvenience, or damage, including direct, special, incidental, or consequential damages, resulting from the use or
inability to use the MKT product, whether resulting from breach of warranty or any other legal theory.
This Warranty is Subject to the Following Conditions:
Specifications: Pump operations must be within discharge pressure and inlet pressure specifications. The pres-
sure regulating valve must be correctly adjusted.
Pumped Fluids: The warranty is void if pump operation commences without sufficient fluid supplied to the
pump. Do not run dry. Do not pump unfiltered cutting fluids or fluids incompatible with rubber
seals. Contact CoolJ et for additional information on questionable fluids.
Lubrication: The warranty is void if pump operation commences without oil in the crankcase. Use only
CoolJ et approved crankcase oil or equivalent.
Your CoolJet System is an important investment. MKT Innovations / CoolJet Systems is
dedicated to supporting that investment. Feel free to contact us.
#7030 SFP/DFP Rev. B 040330 CoolJ et Operation Manual
38
Notes