JE80-1000

ULTRA HIGH PRESSURE

WATER-BLASTER
USER, SERVICE
& PARTS MANUAL
V 3.2

1
Thank you for choosing our water
blaster. For your safety and correct
operation, please carefully read the
information and instructions in this
manual before use.

COMBIJET has no responsibility or liability regarding

misuse of the product or use of this product with third
party products/accessories.

COMBIJET warranty’s is limited to repair or

replacement of faulty items at the time of
manufacture, as per our warranty T&C.

Model: JE80-1000
Technical details:

Working Pressure: 1000 bar / 14500 PSI

Flow-rate (@60Hz): 15 lpm / 3.96 GPM

Electrical Specifications:
Motor: 40.23 HP / 30 kW
Voltage: 400-440V
Running Current: 50-58 A

Dimensions LxWxH: 1750 x 1000 x 1100 mm

Weight: 600 kg

2
TABLE OF CONTENTS
USER, SERVICE & PARTS MANUAL

WARNING & SAFETY PRECAUTIONS ....................................................................................................................................... 5

PROTECTION GEAR ................................................................................................................................................................. 6
MEDICAL EMERGENCY INFORMATION ................................................................................................................................... 7
MACHINE NAMEPLATE ........................................................................................................................................................... 8
SETUP & USE ........................................................................................................................................................................... 9
DAILY INSPECTION ................................................................................................................................................................ 11
PUMP INFORMATION, GUIDELINES AND MAINTENANCE .................................................................................................... 12
MACHINE TROUBLESHOOTING & REPAIR............................................................................................................................. 25
TIGHTENING INSTRUCTIONS ................................................................................................................................................. 28
WARRANTY CONDITIONS...................................................................................................................................................... 29
DISPOSAL .............................................................................................................................................................................. 29
CE DECLARATION OF CONFORMITY...................................................................................................................................... 32
CE DECLARATION OF CONFORMITY...................................................................................................................................... 33
FRAME PARTS ASSEMBLY ..................................................................................................................................................... 35
FRAME PARTS LIST ................................................................................................................................................................ 36
WATER TANK SPARE-PARTS ASSEMBLY ................................................................................................................................ 37
WATER TANK SPARE-PARTS list ........................................................................................................................................ 38
FEED PUMP PARTS ASSEMBLY .............................................................................................................................................. 39
FEED PUMP PARTS LIST..................................................................................................................................................... 39
WATER FILTRATION SYSTEM ASSEMBLY............................................................................................................................... 40
WATER FILTRATION SYSTEM PARTS LIST .......................................................................................................................... 41
MAIN PUMP ASSEMBLY ........................................................................................................................................................ 42
MAIN PUMP ASSEMBLY LIST ............................................................................................................................................. 43
MAIN PUMP SPARE-PARTS ASSEMBLY ................................................................................................................................. 44
PUMP SPARE-PARTS LIST .................................................................................................................................................. 45
PRESSURE REGULATOR VALVE ASSEMBLY............................................................................................................................ 47
PRESSURE REGULATOR VALVE ASSEMBLY PARTS LIST ................................................................................................... 48
COUPLING SPARE PARTS ASSEMBLY ..................................................................................................................................... 49
COUPLING SPARE PARTS LIST ........................................................................................................................................... 49
ELECTRICAL SYSTEM SPARE-PARTS ASSEMBLY ..................................................................................................................... 50
ELECTRICAL SYSTEM SPARE-PARTS LIST ........................................................................................................................... 51
WIRING DIAGRAMS............................................................................................................................................................... 52
DUMP GUN SPARE PARTS ASSEMBLY ................................................................................................................................... 56
DUMP GUN SPARE PARTS LIST ......................................................................................................................................... 57

3
NOZZLE HOLDER-PARTS ASSEMBLY ...................................................................................................................................... 58
NOZZLE HOLDER-PARTS LIST............................................................................................................................................. 59
ORBITAL ROTATING NOZZLE SPARE-PARTS ASSEMBLY ........................................................................................................ 60
ORBITAL ROTATING NOZZLE SPARE-PARTS LIST ............................................................................................................... 61
ORBITAL ROTATING NOZZLE OPERATING INSTRUCTIONS .................................................................................................... 62
ORBITAL ROTATING NOZZLE SAFETY INSTRUCTIONS ........................................................................................................... 66
ULTRA IMPACT NOZZLE SPARE-PARTS ASSEMBLY (OPTIONAL)............................................................................................ 67
ULTRA IMPACT NOZZLE SPARE-PARTS LIST (OPTIONAL) ...................................................................................................... 68
ULTRA-IMPACT NOZZLE MAINTENANCE .............................................................................................................................. 69
ULTRA IMPACT NOZZLE MAINTENANCE ............................................................................................................................... 70
ULTRA IMPACT NOZZLE MAINTENANCE PROCEDURE & SPARE PARTS LIST .................................................................... 70
ULTRA IMPACT NOZZLE TROUBLESHOOTING ....................................................................................................................... 71

4
WARNING & SAFETY PRECAUTIONS
The Unit MUST be grounding during operation to avoid any damage or accident from the electrical
components.

To safeguard the operator who uses the machine and its accessories and as accident prevention and protection
of bystanders and property, the following safety precautions must be observed. Always treat the water blaster
in the same way as any other power-driven high-speed cutting tool!

Never let children or people who have not been properly instructed operate the machine.

Use the electric plug in a proper socket with ground to earth wiring. The entire electrical installation must be
with earth wiring! The motor should be connected to an appropriate earth point.

All electrical installations must be made only by an electrician. A GFCI (Residual current device) is
recommended.

Always keep the high-pressure cleaner and the belonging accessories in good working condition. Check that
the machine and its accessories are free from defects, and in good working condition, with special attention
to the insulation on the electric cable. In case of defect: Do NOT OPERATE THE MACHINE! Get the machine
serviced.

Eye protection must always be worn when operating the machine to protect against repelling or ricocheting
materials hitting the eyes and causing damage.

Ear protection must always be worn when operating the machine to protect against hear loss during operation.

Proper footwear and protective clothing must always be worn when using the equipment to avoid and prevent
damage to the operator.

NEVER direct the jet at yourself. Do not attempt to clean your clothes or footwear with the machine. Be
especially alert when pulling or releasing the trigger as sudden reaction forces will occur.

Precautions must be made to keep bystanders away from the working range. Especially when pulling the
trigger as sudden reaction forces can make changes in the direction of the jet.

NEVER spray-jet on humans or live animals, the high-pressure jet can cause severe injury and/or death.

NEVER spray at electrical equipment, or at the machine itself.

Before service or repair: Make sure the machine is turned off, and pressure is released from the system by
pulling the trigger after shutting down the machine. The machine should be disconnected from the main power
supply by pulling out the electrical plug.

5
PROTECTION GEAR
EYE PROTECTION
Visor Operators must wear visors or goggles to guard against spray and flying
Goggles debris. A combination of both goggles and visor is recommended. It will
protect the eyes and the face during both water-blasting as well as
abrasive water-blasting.

HEAD PROTECTION
Safety helmets must be worn at all time by personnel within the work
area.
Helmet material must be able to withstand mechanical shock exceeding
10G in 8ms without fracturing.

HAND PROTECTION
Shear proof gloves must be worn by the operator at all times.
A glove combination of a cloth inner lining and a water tight outer layer
is preferable.

FOOT PROTECTION
Safety boots with steel toecaps minimum 0.5mm (0.02”) thick must be
worn. The toecap must cover at least 30% of the footwear length. Basic
safety footwear must also be equipped with metatarsal guards to
protect the instep. Safety boots are available in numerous designs.

HEARING PROTECTION
Operators and other personnel exposed to noise levels of more than
90-dBa for more than 1 hour must wear suitable ear protection. Ear
plugs or ear muffs are usually sufficient.

PROTECTIVE CLOTHING
Waterproof clothes protect the operator only from spray and flying
debris. They do NOT deflect direct jet impact.
Therefore, an operator must take care never to point a water jet either
at themselves or other personnel.

6
MEDICAL EMERGENCY INFORMATION
Immediate medical attention should be given to personnel who sustain equipment related injuries
while operating the system. In such cases, it is vital that medical personnel be apprised of all facts
relevant to such injuries. Therefore, all operating personnel should be provided with waterproof
emergency medical alert tags or cards, describing the nature of their work and the possibility of
injury inherent in the use of water jetting equipment. The below example of a standard card can
be printed out or photo copied, bend, laminated and used as medical alert tag.

7
MACHINE NAMEPLATE

8
SETUP & USE
Mount the high-pressure hose on to the water-blaster by screwing the swivel on to the high-pressure fitting
on the side of the cylinder-head (OR right-side of the pressure regulating valve, when that is available).
Mount the dump gun with lance to the ½” high-pressure hose. Always use two wrenches when tightening the
hoses.

Prepare the water supply for the water-blaster, by attaching a ¾” or 1” hose to the supplied low-pressure inlet
coupling on the side of the water tank. Connect the other end of the water supply hose to a fresh water tap.
Open the tap. To prevent water spill always use the float valve inlet.

Connect the main power cords to an earthed 3 phase main power supply. Connect a grounding cable from the
motor grounding point to an appropriate earth point. Turn on the power and push the start button on the
electric panel. Allow the machine a few seconds for the star delta connection to switch over automatically
before using the dump gun.

For the initial start and at the beginning of every job shift, remove any nozzles on the gun, in order to flush
the system from any dirt or particles that might block the nozzles. Press the trigger and let the water flow to
flush the system.

Replace the nozzles onto the gun, get a firm grip with both hands on the gun handle and the lance handle.
Press the trigger on the dump gun and start blasting. Pay special attention to the fact that energizing the gun
causes reaction forces that can cause the jet to change direction.

After the shutdown of the water-blaster, it is always recommended to pull the trigger on the dump gun to
make sure that there is no pressure in the high-pressure hose. Trapped high-pressure can cause severe injury.

Notice
Make sure your local power supply specifications are suitable for the motor need. Refer to the ID-plate located
at the base of the chassis plate.

Onboard vessels

Position the Water-blaster machine behind the super structure or on the poop Deck, securely fastened.
Engage the built-in brake when running the machine.

9
The machine is equipped with the following safety devices
1. MAIN SWITCH: The main switch disconnects the main supply
2. START BUTTON: Starts the machines
3. STOP BUTTON: The stop button stops the machine when pushed in.
4. EMERGENCY STOP BUTTON: The emergency stop button immediately stops the power supply to the
machine when pushed in.
5. FEED PUMP RUN LAMP: Indicates that the feed pump is in operation mode.
6. MAIN PUMP RUN LAMP: Indicates that the main pumps is in operation mode.
7. FEED PUMP FAILURE LAMP: Indicates that the feed pump has a failure.
8. MAIN PUMP FAILURE LAMP: Indicates that the main pump has a failure.
9. POWER ON LAMP: Indicates that the machine in working.
10. HOURMETER: Indicates the total working hours of the machine.
11. OVER LOAD RELAY: The overload relay protects the motor against overloading
12. INLET PRESSURE SENSOR: The sensor prevents the pumps from running dry, by shutting off the
machine when inlet pressure in the main pump falls below 1.3 bar.

UN-PLUG MACHINE WHEN REPAIRING!

11 12

10
DAILY INSPECTION

CHECK LIST

➢ Check the strainer in the water-tank.

➢ Clean if necessary.
➢ Check the oil level on the crankcase of the pump.
➢ Fill up if necessary.
➢ Check for air-bubbles in the suction hose between tank and pump.
➢ If there are bubbles then tighten the hose-clips.
➢ Check high pressure connections for leakage.
➢ NEVER tighten connections under pressure.
➢ Check high pressure hoses for wear and cracks.
➢ Replace if necessary.
➢ Check the power cord for wear and cracks.
➢ Replace if necessary.
➢ Check the air intake grill of the electric motor.
➢ Clean for dust if necessary.

NOTICES:

• To prevent damage to hoses and electrical cord, avoid letting the high-pressure hoses rub against sharp
edges for example manholes or getting squeezed in door openings etc. Replace if necessary.
• Inlet water temperature must be below 60°C (140°F)

11
PUMP INFORMATION, GUIDELINES AND MAINTENANCE
1. GENERAL INFORMATION
1.1 SAFETY SYMBOLS
The “WARNING” symbol here at the side draws the operator’s attention to situations and/or problems
related to the correct operation of the Pump.

The “DANGER” symbol here at the side draws the operator’s attention to situations and/or problems that
could compromise the safety of people.

1.2 PUMP IDENTIFICATION

The Label on the Pump bears the
Model, the Code, the Serial Number and the main technical specifications with the
maximum operational values of the product.
The specimen at the side is an example of a Label and its position on the Pump.

Figure 1

2. INTRODUCTION
The horizontal plunger pump is designed and manufactured to pumps or transfer clean water.
The pump consists of two main sections (see fig.1): a “Power End” and a “Fluid End”.
In the “Power End”, the moving components are in contact with the lubricant and transform the rotary
motion of
the power take-off of the shaft into the alternating horizontal motion of the pistons inside the “Fluid End”,
whose other components are in contact with the water used in the system.
The Pumps are supplied standard with the power take-off of the shaft on the right (see fig.1); on request,
all models can be supplied with power take-off on the left.
The Pumps are generally driven by: electric motors, endothermic petrol or diesel engines and hydraulic
motors, tractor or truck P.T.O. Couplings may be fulfilled by means of transmission shaft, direct flanging,
reduction unit or multiplier, joints, pulleys and belts.

12
 The Pump is supplied to be installed on a more complex machine or plant; the manufacturer of such
machine or plant shall add all the information related to safety of the assembled machine/plant fulfilled.

3. INTENDED USE
The plunger pump is designed to be used in machines or systems for transferring pressurized water, such
as the following for example: High Pressure Cleaning, High Pressure Descaling, Chemical Process.
The temperature of the workplace shall be between: Min. 0°C (32°F) - Max.40°C (104°F)
The Pump cannot be used submerged under any type of liquid.

4. OPERATIONAL RESTRICTION

The specifications of the liquid to be used are described in detail herewith: do not use for different liquids;
in particular, it is NOT possible to use the pump in the following conditions:
• In the presence of water with high salt content, such as seawater for example; for this type of use,
you are recommended to use special pump stainless steel series.
• In workplaces where there is a corrosive or explosive atmosphere.
• In the presence of any liquid that is not compatible with the constructional material of the Pump.
• To pump paint, solvents, fuel and any flammable liquid (not suitable for ATEX workplaces).
• To foodstuffs.
• To wash people, animals, live electrical or electronic equipment.
• To wash the Pump itself.

5. GENERAL WARNINGS
• Never start the Pump under pressure.
• Constantly check the state of wear of the pipes and relevant fittings, especially those under pressure.
Pipes with signs of abrasion or that do not guarantee a perfect seal shall be replaced.
• The Pump must never run dry/without any liquid while in use.
• Protect rotating parts with a cover to prevent contact.
• The Pump is designed to be integrated in a machine or system, with various supply systems, which may
make the noise level vary, even quite substantially. The manufacturer of such machine or system shall
assess the level of noise emitted by the assembled machine or system and inform the user
appropriately, also in relation to the use of suitable personal protection equipment.

6. BEFORE START UP

6.1 LIQUIDS TO BE PUMPED

13
 The Pump is designed and manufactured to transfer clean liquid or non-aggressive watery solutions.
The liquid intaken must be free from sand or other solid particles in suspension.
The liquid intaken shall have viscosity and density similar to water.
The maximum temperature of the liquid to be pumped: 35°C (95°F).
Any other use is not admitted unless authorised in writing by the Technical Department of Combijet.
6.2 INLET, OUTLET AND PORTS OF THE PUMP

The pump (see fig. 2) is equipped with the following fittings:

Fig. 2

A. No. 2 G 1/2" Inlets (also called In-take or Supply fittings); by removing or inverting the sealing caps, they
can be used indifferently on the right or left part of the head of the Pump or they can both be used.

B. No. 5 G 1/2” Outlets (also called Delivery fittings); by removing or inverting the sealing caps, they can all
be used indifferently, as fittings for regulator and maximum pressure valves, gauges, pipes of spray guns or
other high-pressure components. The seal between the sealing caps and head is guaranteed by a special
stainless-steel seat with double taper; the caps and head are machined so that they couple perfectly with
this special seat.

The Inlet and Outlet of the Pump CANNOT be inverted.

C. No. 5 G 1/4" outlet fittings, for collecting the water of the internal “Cooling System”, which consists in
deviating a small amount of supply water into the pump to cool and keep the pistons and high and low-
pressure seals clean, thus increasing their service life. These five fittings can be used in two different
configurations: the standard configuration envisages the use of just one collection pipe of the cooling water,
which must be positioned at the side, opposite the Inlet port used, inverting the position of the male-male
nipple G1/4” and opposite sealing cap if necessary. The second possibility of use envisages closing both side
14
 outlets and using three different collection pipes of the cooling water, to be positioned under the central
casing of the Pump.
In both cases, the water that comes out of the “Cooling System” must be conveyed on the inlet line of the
pump, before the booster pump, or into a dedicated tank.

6.3 INLET CONDITIONS (SUCTION)

The pump must be supplied at an inlet pressure between 2 and 6 bar (0.2 MPa and 0.6 MPa - 29 and 87
PSI). If a Booster Pump is used, which is to be started before the pump, it shall have a minimum flow rate
at least double the flow rate of the model of the pump used; this minimum flow rate must be supplied at
the booster pressure used.
• Avoid any turbulence near the Pump inlet; the discharge of the pressure regulator valve must not be
connected to the supply line of the pump.
• Turbulence must be absolutely avoided near the outlet of the supply tank (inlet line of the Booster
Pump).
The inlet pipeline must comply with the following requirements:
• Any point of the inlet pipeline cannot be smaller than the internal diameter of the Pump inlet.
• Be absolutely leak-proof to avoid any air infiltration.
• Not have 90° bends near the Pump inlet.
• Not have contractions or restrictions.
• Avoid any turbulence near the Pump inlet; the discharge of the pressure regulator valve must not be
connected to the supply line of the pump.
• Turbulence must be absolutely avoided near the outlet of the supply tank (inlet line of the Booster
Pump).
Any other use is not admitted unless authorized in writing by the Technical Department of Combijet.
6.4 FILTERING

The filter must be installed as close as possible to the pump inlet and it must allow 3 times greater than the
flow required by the Pump, it must not cause any contraction or any pressure drop and should be cleaned
on a regular basis to ensure its proper functionality.
The recommended filtration degree is 150 mesh/micron.
6.5 OUTLET CONDITIONS
• A safety valve must be installed on the delivery line of the system.
• Make sure the delivery line and all the accessories are connected correctly, secured firmly, hermetically
sealed and that the pipes are sized appropriately.

15
 • All pressurized pipes must be marked durably with the maximum admitted pressure, which must never
be less than the maximum working pressure of the Pump, written on the Label.
• If there are excessive pulsations in the system where the Pump is fitted, install a correctly sized
pulsation damper (accumulator).

6.6 SPEED AND ROTATION DIRECTION

The rotation speed of the shaft of the Pump must never exceed the RPM written on the Label of the actual
Pump.
The minimum RPM admitted is 700 RPM.
The rotation direction of the shaft of the pump may be clockwise or anticlockwise.
7. CONTROLS ON SYSTEM
7.1 NOZZLE
The nozzle sizes are chosen based on the power supply rating indicated on the machine plate.
Different power supply at the work place (different Voltage and Frequency) will affect the pressure and flow
output of the pump. In such case, different nozzle sizing is required to have the correct pressure output at
the gun.
A deteriorated nozzle could cause a drop in pressure. If the pressure drops, it is advisable to replace the
nozzle with a new one.
Clogged nozzles (due to dirt for example) could cause the pressure to rise. Make sure that the nozzles are
not blocked for correct operation of the machine.

7.2 PRESSURE GAUGE

Install a gauge on the Pump or as near as possible to the outlet of the Pump because the maximum pressure
written on the Pump’s Label refers to the pressure detected on the head of the Pump and not on the nozzle
or on other accessories.

7.3 PRESSURE SAFETY VALVE

The pump is fitted with a Pressure Safety Valve, which protects the pump from running at a pressure
exceeding the maximum pressure of the pump.
Use of the Pump, even for a short period, with a pressure higher than such limit would damage the Pump
itself.
The safety valve shall be compatible with the maximum pressure, flow rate and temperature values written
on the Label.
Incorrect installation of the pressure regulator valve could cause serious personal injuries and damage to
property as well as seriously damaging the actual Pump.
16
All the components of the machine or of the circuit must have technical specifications compatible with the
data written on the Pump’s Label.

8. INSTALLATION, START UP AND SWITCHING OFF

8.1 POSITIONING
The pump is to be handled using exclusively the specific eyebolt supplied, hooking it to a rope or chain with
the specific hook and using suitable lifting equipment.
If the pump is used in a particularly dirty workplace or is exposed to atmospheric agents, you are
recommended
to protect it, respecting the ventilation conditions.

8.2 ASSEMBLY
Fit the Pump on a rigid surface keeping the power take-off and support feet horizontal to ensure correct
drainage in the case of leakage of water or oil. The Pump must be secured firmly on a base, which must be
perfectly aligned with the transmission components. In the case of belt transmission, make sure the pulleys
are aligned and check the tension of the belts.
- In the operational phase, the maximum admitted inclination of the pump is 10°; if you should tilt it more,
this could cause insufficient lubrication of some of the components in the “Power End”.
- The power take-off of the pump shaft must not be connected to the drive unit by means of rigid
components.
Use appropriately sized hoses, both on the inlet and outlet of the Pump, according to the technical
specifications written on the Label.

8.3 START UP
Before starting, check the following:
• Replace the RED cap on the Pump Crankcase with the Oil Vented Plug in the kit of accessories supplied.
• Check the level of oil through the dedicated clear level indicator on the rear cover or via the level rod of
the oil vent cap; top-up if necessary (see paragraph 9.3).
• Make sure all the pipes are connected properly.
• The pressure regulator valve must be set at “0” pressure to favour intake.

17
 • Start the Booster Pump or open the line connected to the Pump inlet, respecting the minimum and
maximum supply pressure values (see paragraph 6.3).

Attention: the pump must never run dry!

Start and run the Pump until all the liquid has discharged from the delivery line without air bubbles.
The presence of air inside the pump during use under pressure could seriously damage the pump itself.
Once the suction cycle has been completed correctly:
• Adjust the pressure regulator valve and take the system to a pressure of approximately 100 bar (10 MPa
– 1450 PSI).
• Let the pump run in these conditions for a couple of minutes, checking that the pipes, connections and
components of the system are in perfect working conditions and making sure there are no leaks or drips
of water.
• At the end of this settling-in and inspection cycle, the system can be taken to the required pressure,
without ever exceeding the maximum pressure written on the nameplate of the pump itself.

8.4 SWITCHING OFF AND STORAGE

Switching off:
1. Let the system work for a couple of minutes, setting the pressure regulator valve at “0”.
2. Stop the Pump drive.
3. Switch the booster pump off or close the pressurized supply line. If stored away or not used for a
long period of time, follow the instructions given in points 1, 2 and 3, then:
4. Disconnect the supply pipe from the inlet port of the Pump, letting all the water in the Pump’s head
drain out.
5. Disconnect the delivery pipe from the outlet port of the Pump and also the pipe or pipes of the
“Cooling System”.
6. Start the Pump drive and switch it off after 5 seconds so that all the water left inside the pump is
expelled.
7. Put some grease on the threads of the Pump where there are no longer any pipes connected.
8. Do not wash the Pump externally: water could get into the Pump crankcase, for example through
the oil vented plug.
After switching off, the Pump could remain very hot for some time.
Do not throw the liquid used to wash the Pump outdoors but observe current standards.

8.5 PRECAUTIONS AGAINST FREEZING

If shutdown during winter or in the case of places and seasons subject to frost, once the Pump has finished
working, run it for the time required to Pump an emulsion of 50% of clean water and 50% of antifreeze fluid
through it in order to prevent freezing and damage to the Pump.

18
 The Pump must not be used to Pump antifreeze fluid that is not mixed with water.
In the presence of ice or very cold temperatures at the workplace, the Pump must never be started,
otherwise the Pump could be seriously damaged. To start the system, the whole circuit must be completely
defrosted.

9. MAINTENANCE

Maintenance operations must be carried out by qualified and authorized personnel.

Use appropriate tools to disassemble and assemble the various components of the pump. Each tool must
be specific for the individual job to be done. The use of unsuitable tools could damage the pump irreparably.

9.1 ROUTINE MAINTENANCE

If the Pump is used for light-duty purposes, the following routine maintenance jobs are advised:
- After the first 50 hours of use and every 250 hours: Check the torque setting of the blind locking nuts of
the head
(See TIGHTENING INSTRUCTIONS section below).
- Every 500 hours: Check or replace water packing seals
- Every 1000 hours: Check or replace the valves. Attention: whenever the valves are disassembled, the O-
Rings must be replaced
(See Pump Exploded View Diagram – Fluid End O-rings Kit CJL80K1289).
For heavy-duty purposes, carry out the maintenance jobs more often.

19
9.2 MAINTENANCE GUIDE

20
21
22
23
 9.3 LUBRICATION
The Pump comes supplied with the correct amount of lubrication oil which, in the case of this particular
pump, is 3.4 Kg (7.5 Lbs.) - 3.8 L. (1.0 Gal.)
Check the oil level inside the pump daily via the clear level indicator on the rear cover or via the level rod of
the oil vent cap.
The following oil changes are recommended:

• After the first 50 hours of use.

• Every 500 hours of use.
• In any case, the oil has to be changed once a year.

Use OIL type CLP 220 or an alternative Gear Oil type SAE 85W-90.

Here are some recommended types of oil:

BRAND TYPE
AGIP BLASIA 220
BP ENERGOL GR-XP 220
CASTROL ALPHA SP 220
ESSO SPARTAN EP 220
MOBIL MOBILGEAR XMP 220
SHELL OMALA 220
TOTAL CARTER EP 220

The oil is to be changed by draining it through the dedicated bottom discharge cap and strictly with the
pump stopped.

DO NOT START THE PUMP IF THERE IS NO OIL IN THE PUMP!

During maintenance, you are recommended to:

• Use and wear suitable personal protection equipment (i.e. gloves).

• Wait for the machine to cool down and to have stopped completely.
During maintenance, do not throw residues outdoors but observe current standards.
If the Pump is to be scrapped:
1. Separate the various parts depending on their type (i.e. plastic, harmful fluids, metal etc.).

2. Use public or private waste disposal systems envisaged by local law to dispose of waste.
3. This device could contain harmful substances: improper use or incorrect disposal could have
negative effects on human health and on the environment.

24
MACHINE TROUBLESHOOTING & REPAIR
PROBLEMS PROBABLE CAUSES
The pump is not supplied
correctly and is running dry.
The Pump does not make any
The valves are blocked.
noise after starting its drive.
The delivery line is obstructed
and is
stopping the air inside the pump
from being let out of the system.
Excessive running speed.
Excessive working pressure.
The belts of the pulleys are too
tight.
The power take-off of the pump
The Pump overheats.
shaft is not perfectly aligned withpump shaft perfectly with that of
that of the drive.
Not enough oil inside the pump.
An unsuitable type of oil has been Use nothing but the
put in the pump.
The oil has deteriorated due to
oxidation.
25
SOLUTIONS
Switch the pump off immediately!
Check the pressurized supply line
and the correct operation of the
booster pump.
Inspect the valves.
Clear any obstructions on the
delivery line.
Respect the maximum running
speed (RPM) written on the
nameplate of the Pump.
Respect the maximum pressure
written on the nameplate of the
Pump.
Tension the belts correctly.
Align the power take-off of the
the drive.
Check the oil level; top-up if
necessary.
recommended types of oil.
Change the oil.
 Incorrect or worn or plugged
nozzle.
Belt slippage.
Air leak in inlet plumbing.
Inlet suction strainer clogged or
improper size.
Worn seals.
Abrasives in Pumped fluid; severe
The Pump doesn’t reach required cavitation; inadequate water
pressure. supply.
Pressure gauge is broken or not
registering accurately.
Relief / unloader valve stuck,
partially plugged or improperly
adjusted.
Dirty or worn inlet or outlet
valves.
Leaky outlet hose.
Air leak in inlet plumbing.
Inlet strainer clogged or improper
size or insufficient supply of water
to the Pump.
Dirty or worn inlet or outlet
Pump is noisy. valves.
Worn seals or o-rings.
Plugged inlet filter or improper
size.
Pulley loose on crankshaft or
worn key.
Broken or worn bearings.
Worn low pressure seal or o-ring.
Water leakage between
Cracked plunger.
head and body.
High humidity in air (condensing).
Water in crankcase.
Worn crankcase oil seal.
Oil is changing color into white.
Worn low pressure seal.
Oil leak between crankcase
Worn crankcase oil seal.
and head.
Worn crankshaft oil seal.
Worn bearing case o-ring.
Bad bearings.
26
Change to proper size nozzle;
replace nozzle or clean nozzle.
Tighten or replace belt.
Check or replace hoses or fittings.
Check and clean, use adequate
size.
Install and maintain proper filter.
Replace seals.
Check with new gauge; replace
worn or damaged gauge.
Adjust or repair or replace relief /
unloader valve.
Check and clean or replace valves
Check or replace discharge hoses
or fittings.
Check or replace hoses or fittings.
Check and clean, use adequate
size; increase water supply if not
sufficient.
Check and clean or replace
valves.
Replace seals or o-rings.
Clean or replace filter.
Check pulleys and key.
Replace bearings.
Replace seal or o-ring.
Install new plunger.
Change oil every 250 hours
instead of
500.
Replace crankcase oil seal.
Replace seal.
Check plunger rod.
Replace crankcase oil seal.
Replace crankshaft oil seal.
Replace bearing case o-ring.
Replace bearings.
 Oil leak in the area of
crankshaft.
Damaged or improperly
installed sight glass or
Oil leak at the rear end of the Replace sight glass, plug or
crankcase cover seal or drain
Pump. seals.
plug.
Scored plungers. Replace plungers.
Over pressure in inlet
Reduce inlet pressure.
manifold.
Abrasive material in the fluid
Install proper filter on Pump
being
inlet plumbing.
Pumped.
Frequent or premature failure Use clean water or contact
of the packing. Corrosive additives in the fluid Combijet Technical Service
being Pumped. Department for more
information
Do not run Pump without
Running Pump dry.
fluid.
Check or replace hoses or
Air leak in inlet plumbing.
fittings.
Pulsation damper pressure too
Check and repressure.
low.
Pump – Drive connection not Check and modify the Pump –
Excessive vibrations.
suitable. Drive connection if necessary.
Dirty or worn inlet or outlet Check and clean or replace
valves. valves.

27
TIGHTENING INSTRUCTIONS

POS. DESCRIPTION Nm lbf•ft Loctite

1 Head Blind Nuts 130 96
2 Inlet and Outlet Plugs 130 96 243
3 Stud Bolt 30 22 243
4 Cooling System” Connector 50 37
5 Bearing Flange Bolts 50 37
6 Oil Discharge Plug 25 19
7 Rear Cover Screws 11 8
8 Connecting Rod Screws 25 19 243
9 Pin Screws 6 4.5 243
10 Plunger Bolts 6 4.5 243

28
WARRANTY CONDITIONS

All our machines are subjected to strict tests and are covered against manufacturing defects in accordance with
applicable regulations.

The warranty is effective from the date of purchase.

The warranty is only applicable if the machine is used in accordance with the instructions in this manual.

The following are not included in the warranty:

- Parts subject to normal wear. – Rubber parts, nozzles, hoses, filters and other consumable parts and accessories.

- Accidental damage, caused by transport, neglect or inadequate treatment, incorrect or improper use and installation
failing

- The warranty shall not cover any cleaning operations to which the operative components may be subjected, such as
clogged nozzles and filter blocked due to limestone.

DISPOSAL

As the owner of electrical or electronic equipment, the law (in accordance with the EU Directive
2002/96/EC of 27 January 2003 on waste from electrical and electronic equipment and the national laws of
the EU Member States that have implemented this Directive) prohibits you from disposing of this product
or its electrical / electronic accessories as municipal solid waste and obliges you to make use of the
appropriate waste collection facilities.

The product can be disposed of by returning it to the distributor when a new product is purchased. The new product
must be equivalent to that being disposed of.

Disposing of the product in the environment can cause great harm to the environment itself and human health.

The symbol in the figure indicates the urban waste containers and it is strictly prohibited to dispose of the equipment
in these containers. Non-compliance with the regulations stipulated in the Directive 2002/96/EC and the decrees
implemented in the various EU Member States is administratively punishable.

29
 CE DECLARATION OF CONFORMITY

We hereby declare that the machine described below complies with the relevant basic safety
and health requirements of the EU Directives, both in its basic design and construction as
well as in the version put into circulation by us. This declaration shall cease to be valid if the
machine is modified without our prior approval.
Manufacturer or representative: COMBIJET MANUFACTURING LTD

Product type: HIGH PRESSURE WATER JET CLEANER

Product designation: JE80-1000

The designated product(s) is (are) in conformity with the provisions of the following
European Directives.

2006/42/EC Directive of the European Parliament and of the Council of 17 May 2006 on machinery

2014/68/EU Directive of the European Parliament and of the Council of 15 May 2014 on the
harmonisation of the laws of the Member States relating to the making available on the
market of pressure equipment Text with EEA relevance.
2014/35/EU Directive of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of the Member States relating to the making available on
the market of electrical equipment designed for use within certain voltage limits.
2014/30/EU Directive of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of the laws of the Member States relating to electromagnetic
compatibility.
2002/44/EC Directive of the European Parliament and of the Council of 25 June 2002 on the
minimum health and safety requirements regarding the exposure of workers to the
risks arising from physical agents (vibration).
2000/14/EC Directive of the European Parliament and of the Council of 12 December 2006 on the
harmonization of the laws of Member States relating to electrical equipment designed
for use within certain voltage limit.

Last two digits of the year in which the CE marking was affixed: 21

Place and date of signatures:

Limassol, Cyprus Serial
Number:
Names: Constantinos Foutas Signature:

This declaration of conformity is issued under the sole responsibility of the manufacturer. It
certifies compliance with the indicated Directives but implies no warranty of properties.

(1/2)

32
 CE DECLARATION OF CONFORMITY

The conformity of the designated product(s) with the provisions of the European Directive 2014/35/EU
is given by the compliance with the following European Standard(s). If not elsewhere/otherwise
indicated the edition/amendment as referenced below applies.

EN 60335-1:2012 Directive of the European Parliament and of the Council of 17 May 2006 on
machinery
EN 60335–2– Household and similar electrical appliances – Safety - Particular
79:2009 requirements for high pressure cleaners and steam cleaners

The conformity of the designated product(s) with the provisions of the European Directive 2014/30/EU
is given by the compliance with the following European Standard(s). If not elsewhere/otherwise
indicated the edition/amendment as referenced below applies.

EN55014– Electromagnetic compatibility. Requirements for household appliances,

1:2006+A1:2009 electric tools and similar apparatus.
EN55014– Electromagnetic compatibility - Requirements for household
2:1997+A2:2008 appliances, electric tools and similar apparatus
EN 61000-3-2:2006+ Electromagnetic compatibility (EMC)—Part 3-2: Limits—Limits for harmonic
A1:2009+ current emissions (equipment input current ≤ 16 A per phase)
A2:2009
EN 61000-3-3:2008 Electromagnetic compatibility (EMC)—Part 3-3: Limits—Limitation of voltage
changes, voltage fluctuations and flicker in public low voltage supply
systems, for equipment with rated current ≤ 16 A per phase and not
subjected to conditional connection
EN 62233:2008 Measurement methods for electromagnetic fields of household appliances
and similar apparatus with regard to human exposure
EN 61439-1:2011 Low-voltage switchgear and control gear assemblies
EN 1825-1:2004 Grease separators. Principles of design, performance and testing, marking
and quality control
EN 55014-1/2 1- Applies to the conduction and the radiation of radio-frequency
disturbances from appliances whose main functions are performed by
motors and switching or regulating devices, unless the r.f. energy is
intentionally generated or intended for illumination. It includes such
equipment as: household electrical appliances, electric tools, regulating
controls using semiconductor devices, motor-driven electro-medical
apparatus, electric/ electronic toys, automatic dispensing machines as well
as cine or slide projectors.
2-Specifies the immunity requirements in relation to continuous and
transient, conducted and radiated electromagnetic disturbances, including
electrostatic discharges, for the above-mentioned apparatus. Apparatus
may incorporate motors, heating elements or their combination, may contain
electric or electronic circuitry, and may be powered by the mains, by
batteries, or by any other electrical power source. Immunity requirements in
the frequency range 0 Hz to 400 GHz are covered.
EN ISO 1200-1/2 Safety of machinery — General principles for design — Risk assessment
and risk reduction
(2/2)

33
PAGE INTENTIONALLY LEFT BLANK

34
FRAME PARTS ASSEMBLY

35
FRAME PARTS LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL10M0010 FRAME RIGHT 1
2 CJL10M0011 S/S REINFORCMENT ROD - BACK 1
3 CJL10M0004 FRAME LEFT 1
4 CJL10M0010 REINFORCMENT ROD – MIDDLE 1
5 CJL10M0012 REINFORCMENT ROD – FRONT 1
6 CJL10M0002 MAIN FRAME 1
7 CJ20120663 AXLE 1
8 CJL10M0122 STEEL PLATE 1
9 CJL800SW M8 SPLIT LOCK WASHER 15
10 CJL00830B M8X30 BOLT 15
11 CJL800FW M8 WASHER 15
12 CJL100FW M10 WASHER 30
13 CJL01030B M10X30 BOLT 14
14 CJ20120606 CASTOR WHEEL 1
15 CJL01030B M10X30 BOLT 4
16 CJL100SW M10 SPLIT LOCK WASHER 12
17 CJL1000N M10 NUT 12
18 CJL10F0119 ANTIVIBRATION TAPE LENGTH: 3M 1
19 CJL80175TR THREADED RIVET M8X1.25 L:17.5mm 10
20 CJ20120466 WHEELS 2
21 CJL0221CC CIRCLIP FOR 25MM SHAFT 2
22 CJL37022 LOCK BREAK 2
23 CJL8000N M8 NUT 8

36
WATER TANK SPARE-PARTS ASSEMBLY

37
WATER TANK SPARE-PARTS LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL10T01 WATER TANK 1
2 CJEB08F08F FEMALE ELBOW ½’’ 3
3 CJBR0600M BREATHER ¼’’ MALE 1
4 CJIHCF12000 INLET HOSE COUPLING ¾’’ F 1
5 CJFV1M12000 FLOAT VALVE ¾’’ M 1
6 CJEP1F06000 FEMALE PLUG ¼’’ 1
7 CJRD1M12F06 REDUCER ½’’ TO ¼’’ M/F 3
8 CJCE1M04000 MALE QUICK CONNECTOR ELBOW ¼’’ TO 10MM TUBING 1
9 CJL40168 25MM FLEXIBLE HOSE FROM WATER TANK TO FEED PUMP INLET LENGTH: 0.5M 1
10 CJL40168 HOSE CLIP 29-31MM 2
10MM TUBING FROM UHP PUMP COOLING LINE
11 CJL10W0145 1
LENGTH: 0.7M
12 CJL34974 NIPPLE ¼’’ LONG 1
13 CJHA1F12000 FEMALE HOSE ADAPTOR ¾’’ TO 25MM FLEX. HOSE 1
14 CJWOC12000 WATER TANK OUTLET ¾’’ 1
* CJL10T010 WATER TANK COMPLETE 1

38
FEED PUMP PARTS ASSEMBLY

FEED PUMP PARTS LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL90M0042 FEED PUMP 60Hz 1
1 CJL90M0041 FEED PUMP 50Hz 1
2 CJHA1M16000 HOSE ADAPTOR 1’’ M TO 25MM DIAM HOSE 2
3 CJRD1M20M16 MALE REDUCER 1 ¼’’ TO 1’’ 1
4 CJEL1F16000 FEMALE ELBOW 1’’ 1

39
WATER FILTRATION SYSTEM ASSEMBLY

40
WATER FILTRATION SYSTEM PARTS LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL10W0103 HOUSING FOR FILTER CARTRIDGE 1
2 CJL10W0126 PRESSURE GAUGE DN40 1/8’’ M 2
3 CJEP1M02000 END PLUG 1/8’’ M 2
4 CJL10W0148 TOP SCREW 1
5 CJL10W0167 WATER FILTRATION SYSTEM SUPPORT 1
6 CJHAM12000 HOSE ADAPTOR ¾’’ M TO 25MM DIAM HOSE 2
7 CJNP12M12M NIPPLE ¾’’ 1
8 CJTE1F12000 FEMALE TEE ¾’’ 1
9 CJL33950 PRESSURE SENSOR 1
10 CJL10W0143 WATER FILTRATION CASING HEAD 1
11 CJL40168 25MM FLEXIBLE HOSE FROM FEED PUMP TO WATER FILTRATION SYSTEM LENGTH:0.7M 1
25MM FLEXIBLE HOSE FROM WATER FILTRATION SYSTEM TO LOW PRESSURE INLET OF THE MAIN PUMP
12 CJL40168 1
LENGTH: 0.3M
13 CJL40168 HOSE CLIP 29-31MM 4
14 CJL90W0320 FILTER CARTRIDGE 5μm 1
15 CJL00815B BOLT M8X15 4
16 CJL800SW M8 SLIT LOCK WASHER 4
17 CJL800FW M8 WASHER 4
18 CJL90W0013 WATER FILTRATION HOUSING COMPLETE (POS.1,2,3,4,5,10,15,16,17) 1
19 CJL10W0123 TEFLON SEALING WASHER 83.5x3x3 1
20 CJL10W0151 TEFLON SEALING WASHER 18.5x2.8x3 1

41
MAIN PUMP ASSEMBLY

42
MAIN PUMP ASSEMBLY LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL10P0085 UHP PUMP 1000 BAR 1
2 CJL90P0042 COMBIJET HP GAUGE ½’’ M 1
3 CJL38122 SAFETY VALVE 1
4 CJL10P0069 HP GAUGE HOLDER ADAPTOR ½’’ 1
5 CJL80P6350 HIGH PRESSURE SEEL 1
6 S/S ADAPTOR ½’’ 1
7 CJRD12M08M REDUCING ADAPTOR ½’’-¾’’ 1
8 CJHAM12000 HOSE ADAPTOR ¾’’ M TO 25MM DIAM HOSE 1
9 HOSE BARB FOR 25mm WATER HOSE ¾’’ THRIED 1
10 HOSE CLIP 25mm 1
11 WATER HOSE 25mm 1
* SET BOLT, FLAT WASHER, SPLIT LOCK WASHER M10 6
CJL01035B BOLT M10X35 6
12
CJL100FW FLAT WASHER M10 6
CJL100SW SPLIT LOCK WASHER M10 6
13 CJL10M0017 COUPLING HOUSING 1
14 CJL90C0001 COUPLING HALVE 1
15 CJL10C0181 M12X30 HEADLESS ALLEN SCREW 2
16 CJL90C0018 COUPLING RUBBER ELEMENT 1

43
MAIN PUMP SPARE-PARTS ASSEMBLY

44
PUMP SPARE-PARTS LIST

POS PART NO DESCRIPTION KIT QTY POS PART NO DESCRIPTION KIT QTY
1 CJL80P1456 Crankshaft 1 29 CJL80P4180 Connector G1/4” 1
2 CJL80P2371 Crankshaft Oil Seal CJL80K5690 1 30 CJL80P1010 Bearing Flange O-Ring CJL80K5690 2
3 CJL80P2748 Plunger Guide Oil Seal CJL80K5690 3 31 CJL80P6666 Sleeve O-Ring CJL80K1289 6
4 CJL80P0013 Valve Elastic Ring, inlet side 3 32 CJL80P4030 Body O-Ring CJL80K1289 3
5 CJL80P1613 Plunger Guide 3 33 CJL80P0203 Valve O-Ring, outlet side CJL80K1289 3
6 CJL80P2118 Upper Ring CJL80K5434 3 34 CJL80P3002 Valve O-Ring, inlet side CJL80K1289 3
7 CJL80P4237 Back up Ring, outlet side CJL80K1289 3 35 CJL80P0763 Valve Seat O-Ring CJL80K1289 3
8 CJL80P2844 Back up Ring, inlet side CJL80K1289 6 36 CJL80P0087 Valve Plate, inlet side CJL80K1824 3
9 CJL80P0015 Body, “Cooling System” 1 37 CJL80P1000 Valve Plate, outlet side CJL80K1824 3
10 CJL80P7778 Sleeve 3 38 CJL80P0864 Plunger 3
11 CJL80P2880 Back Cover 1 39 CJL80P9999 Stud 8
12 CJL80P0001 Crankcase 1 40 CJL80P1280 Dust Plate 1
13 CJL80P0099 Bearing 2 41 CJL80P8014 Pressure Ring CJL80K5434 3
14 CJL80P1111 Cap 1 42 CJL80P5720 Lifting Eye Bolt 1
15 CJL80P4120 Plunger Disk 3 43 CJL80P4017 Rivet 2
16 CJL80P4899 Blind Nut 8 44 CJL80P0344 Head Washer 8
17 CJL80P2213 Bearing Flange 2 45 CJL80P9876 Washer D.8 6
18 CJL80P3333 Valve Cage, inlet side 3 46 CJL80P1880 Washer, D.8 mm 6
19 CJL80P4545 Valve Cage, outlet side 3 47 CJL80P1927 Washer, D.10 mm 12
20 CJL80P1920 Back Cover Gasket CJL80K5690 1 48 CJL80P2014 S.S. Washer, D.5 mm 9
21 CJL80P2526 Flat Gasket G1/2” 1 50 CJL80P6571 Valve Seat 3
22 CJL80P4113 Flat Gasket G3/8” CJL80K5690 2 51 CJL80P6350 Conical Seat 4
23 CJL80P4843 Flat Gasket G1/4” 5 52 CJL80P1990 Pin 3
24 CJL80P2122 Plunger Bushing 3 53 CJL80P1600 Bearing Snap Ring 2
25 High and Low-Pressure Water CJL80K3582 3 54 CJL80P7532 Pressure Ring Snap Ring 3
CJL80P1100
Seals 55 CJL80P8423 Plug G1/2” for conical seal 5
26 CJL80P8888 Key 1 56 CJL80P0869 Plug G3/8” 2
27 CJL80P8147 Valve Spring, inlet side 3 57 CJL80P2487 Plug G1/4” 4
28 CJL80P1313 Valve Spring, outlet side 3 58 CJL80P2200 Sight Glass Oil Plug G3/4” 1

45
POS PART NO DESCRIPTION KIT QTY
59 CJL80P3513 Head 1
60 CJL80P0962 Oil Vented Plug G1/2” 1
61 CJL80P1300 Bolt, M10x30 12
62 CJL80P1800 S.S. Bolt, M6x10 3
63 CJL80P7400 Screw, M8x40 6
64 CJL80P6010 Screw, M6x40 10
65 CJL80P2828 Screw, M5x12 6
66 CJL80P1718 Self-Threading Screw, D.5,5x13 2
67 CJL80P6742 S.S. Bolt, M5x12 9
68 CJL80P1380 Connecting Rod Assembly 3
69 CJL80P2671 Connecting Rod-Plunger Guide Assembly 3
70 CJL80P1421 Crankcase Assembly 1
70 CJL80P1821 Complete Valve Assembly 3
* CJL80K1289 FLUID END O-RING KIT 1
* CJL80K5690 POWER END OIL SEAL AND GASKET 1
* CJL80K1824 VALVES KIT 1
* CJL80K5434 BRASS RING KIT 1
* CJL80K3582 HIGH- AND LOW-PRESSURE WATER SEALS 1

46
PRESSURE REGULATOR VALVE ASSEMBLY

47
PRESSURE REGULATOR VALVE ASSEMBLY PARTS LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL80V0211 BYPASS HOSE ¼’’ BSP TO 3/8’’ JIC 1
2 CJL40145 PRESSURE REGULATOR VALVE 30KSPI 1
3 CJL34738 GLAND NUT ¼’’ 2
4 CJL34737 COLLAR NUT ¼’’ 2
5 CJL34739 HIGH PRESSURE PIPE ¼’’ S/S 316 1
6 CJL30444 NIPPLE 9/16’’ JIC 1
7 CJL80V0225 COMPLETE PRESSURE REGULATOR VALVE 30KPSI 1
8 CJL37054 BRACKET FOR PRESS. REGUL. VALVE

48
COUPLING SPARE PARTS ASSEMBLY

COUPLING SPARE PARTS LIST

POS. PART NO. DESCRIPTION QTY.

1 CJL90C0018 RUBBER ELEMENT 1
2 CJL90C0001 COUPLING HALVES 2
3 CJL10C0181 SCREW M12X30 ALLEN HEADLESS 4
4 CJL90C0068 PUMP SHAFT COLLAR ɸ32mm 1
5 CJL90C0340 MOTOR SHAFT COLLAR ɸ65mm 1
6 CJL90C0360 COMPLETE COUPLING 1

49
ELECTRICAL SYSTEM SPARE-PARTS ASSEMBLY

50
ELECTRICAL SYSTEM SPARE-PARTS LIST

POS PART NO DESCRIPTION QTY POS PART NO DESCRIPTION QTY

1 CJl10E0030 ELECTRICAL PANEL BASE 1 30 CJL90E0118 MCB 2
2 ELECTRICAL PANEL RUBBER MOUNTS D:30mm X 31 CJL90E0114 MCB 1
CJl10E0031 4
L:40mm M8X25 32 CJL90E0116 MCB 1
3 CJL800SW M8 SPLIT WASHER 8 33 CJL10E0166 2 CONDUCTOR TERMINAL 2
4 CJL8000N M8 NUT 8 34 CJL10E0108 SWITCHING POWER SUPPLY S-48-24 1
5 CJL800FW M8 WASHER 8
6 CJL10B01 ELECTRICAL PANEL ENCLOSURE S/S304 1
7 * PANEL RAIL SUPPORTING NUTS 4
8 CJL10E25 HOURMETER 1
9 CJL10E0164 GLUND NUT M20 2
10 CJL10E0127 GLUND NUT M32 1
11 CJL0E07 ROTARY ON/OFF SWITCH 1
12 CJL10E13 LED LAMP HOLDER – GREEN 2
13 CJL10E17 MOUNTING ADAPTER 8
14 CJL10E16 LED LAMP HOLDER – RED 2
15 CJL10E09 PILOT LIGHT HEAD – RED 2
16 CJL10E15 LED LAMP HOLDER – WHITE 1
17 CJL10E14 PILOT HEAD LIGHT – TRASPARENT 1
18 CJL10E21 PUSH BUTTON – GREEN 1
19 CJL10E10 PILOT LIGHT HEAD – GREEN 2
20 CJL10E22 PUSH BUTTON – RED 1
21 CJL10E06 AUXILIARY CONTACT -NO 1
22 CJL10E08 AUXILIARY CONTACT – NC 2
23 CJL10E20 MUSHROOM HEAD PUSH BUTTON – RED 1
24 CJL10E01 MOTOR PROTECTION CIRCUIT BREAKER 1
25 CJL10E11 TIME RELAY 2
26 CJL10E24 TRANSFORMER 1
27 CJL10E03 3 POLE CONTACTOR 25A 2
28 CJL10E04 3 POLE CONTACTOR 38A 2
29 CJL10E05 AUXILIARY CONTACTOR CENT. MOUNT 4

51
WIRING DIAGRAMS

52
53
54
55
DUMP GUN SPARE PARTS ASSEMBLY

56
DUMP GUN SPARE PARTS LIST

POS PART NO DESCRIPTION QTY

* CJL9030860 DUMP GUN ASSY – 15KPSI 1
1 CJL90G0043 VALVE HOUSING 1
2 * CARTIDGE FOR DUMP GUN 1
2a CJL90G0066 ADAPTOR CAP 1
2b CJL10G0123 O-RING 23X2.7 1
2c CJL10G0102 O-RING 10 x 2 2
2d CJL90G0024 REP KIT 40KPSI 1
3 CJL90G0144 TRIGGER HANDLE ASSY 1
4 CJL90G0004 M5X25 ALLEN BOLT 4
5 CJL90G0161 GLAND NUT 9/16’’ 4
6 CJL90G0162 GLAND NUT COLLAR 1 1/8’’ 4
7 CJL10G0144 SHOULDER SUPPORT CONNECTING TUBE 1
8 CJL90G0145 SHOULDER SUPPORT 1
9 CJL10G0127 BENDED PIPE 20KPSI LENGTH 0.3m 1
10 CJL40179 ADAPTOR 1 1/8’’ TO ½’’ F/M 1
11 CJL34123 UHP HOSE 1250BAR 20m 1
12 CJL90G0095 DUMP TUBE 1
13 CJL10G0146 LANCE 20KPSI LENGTH 0.7 m 1
14 CJL10D0013 SIDE HANDLE COMPLETE (INLC. CJL10D006) 1
15a CJL37036 NOZZLE HOLDER 1
15b CJL90N0398 ORBITAL ROTATING NOZZLE 1
15c CJL90N0300 ULTRA IMPACT ROTATING NOZZLE 1

57
NOZZLE HOLDER-PARTS ASSEMBLY

58
NOZZLE HOLDER-PARTS LIST

POS. ITEM NO. DESCRIPTION QTY.

1 CJL37024 NOZZLE HOLDER CAP 1
2 CJL37025 O-RING 1
3 CJL37026 FAN JET NOZZLE 1
3 CJL37027 STRAIGHT JET NOZZLE 1
4 CJL37028 ADAPTER 1
5 CJL90G0162 GLAND NUT COLLAR 1 1/8’’ 1
6 CJL90G0161 GLAND NUT 9/16’’ 1

59
ORBITAL ROTATING NOZZLE SPARE-PARTS ASSEMBLY

60
ORBITAL ROTATING NOZZLE SPARE-PARTS LIST

POS. ITEM NO. DESCRIPTION QTY.

* CJL90N0398 ORBITAL ROTATING NOZZLE 0.95 (for 60 Hz model) *
1 CJL90N0208 FRONT COVER 1
2 CJL90N0209 O-RING D 28 x 2 1
3 CJL90N0210 NOZZLE BODY 1
4 CJL90N0211 O-RING D7.1 x 1.6 1
5 CJL90N0293 ROTOR FOR 0.95 (For 60Hz model) 1
6 CJL90N0876 DRIVING TUBE 2 x 1.00 (For 60Hz model) 1
7 CJL90N0217 O-RING D14 x 2 1
8 CJL90N0218 O-RING D28 x 2 1
9 CJL90N0219 INLET COVER 1

61
ORBITAL ROTATING NOZZLE OPERATING INSTRUCTIONS
1. The nozzle has to be controlled regularly by a mechanic.

• The rotor (C) must move freely in the nozzle (shake the orbital rotating nozzle)
• The front cover (A) and the body (D) are usually not needed to disassemble, the tightening tough has to
be periodically controlled.
• Unscrew the inlet cover (F) from the body (D) and remove the rotor (C). Inspect the rotor (C) visually for
damages, control especially the tungsten carbide inserts, the tungsten carbide seat and the plastic
cylinder of the rotor.
If all parts of the nozzle are undamaged, clean it and reinsert the rotor (C) into the body (D) and screw the body
on the inlet cover after having lubricated the threads.
If a part is damaged, replace it. Always replace together rotor/seat.

2. During Work
• Drain the pipes before mounting the rotating nozzle. The pressurizing must be progressive to get out
the air of the body. A too fast rise of pressure risks a premature damage of the nozzle. Hold the lance
pointed downward to ensure a proper seal is created between the rotor tip and the seat and until the
nozzle turns round.
The rotation will accelerate until a regular revolution speed is reached. There are sometimes slight variations of
the revolution speed which is due to the grinding of the tungsten carbide insert on its seat. After this you can
work in any position.
• Generally, the distance between the nozzle and the work area is bigger than with a standard rotating
nozzle. Begin with a distance around 20 to 30 cm. Look for an ideal work distance in moving closer or
away the jet of the surface.

• Whilst working with the nozzle, you can notice the following phenomena:
Important variation of the rotating speed: wear of the plastic cylinder of the rotor, increase of the contact surface
between insert and seat or damage of the back-metal part of the rotor.

The water cone is not uniform: there are one or several round jets in the cone which are due to a bad tightness between
insert and seat. Very important vibrations in the lance: plastic cylinder of the rotor is badly damaged, out-of-balance of
the rotor, the pressure or/and the flow rate are not adapted on the parameters rotor/driving tube or the lance is too
weak.

As soon as one of those phenomena appears, immediately stop to work, control the rotor, the seat and the inner side of
the body for any wear or damage and change if necessary.

62
PARTICULAR POINTS TO OBSERVE

a) Visual verification of the unit rotor/seat:

• Rotor

The plastic cylinder must have a regular wear, it may not have any material torn off, its wear does not have to allow the
metallic back part of the rotor to rub against the body (D). The sphere of the insert (part which is in contact with the
seat) must be without any scratches which proves that there is dirt penetrating. These scratches can be very small
(some microns), it is desirable to have a lens. The interior of the insert has to be spherical. The rotor does not have the
back part damaged, the metal must not be squeezed (proof that the rotor knocks against the inlet cover or rubs against
the driving tube.

• Seat

The seat must be without any scratches or nicks of material (parts on contact with the insert), use a lens for the
verification.

b) Verification of the inlet cover (F):

It must not have any important scratches on the parts which are in contact with the rotor, proof of too much play or of
important vibrations.

c) Verification of the body (D):

The inside of the body at the height of the plastic cylinder has to be completely smooth and without scratches and wear.
If this is not the case it has to be changed.

Disassembly and reassembly of the seat (B)

The front cover (A) and the body (D) are never disassembled, the tightening must be controlled periodically. The

3. Disassembling and the reassembling of the seat has to be made only in the following manner:
• Before taking apart, clean the nozzle with water.
• Unscrew the body (D) and the front cover (A) from the inlet cover (F)
• Remove the seat with our special mounting tool. (Art.no.10269)
• Grease the O-ring-seal of the new seat and put it back in place using the special mounting tool. Insure that the
seat is properly fitted.

63
 4. Reassembly
• Clean and check the thread and the O-Ring if there are any damages. Grease the thread and the O-Ring with
grease for stainless steel.
• Place the rotor (C) back into the unit body (D)/front cover (A) and hold the lance pointed downward.
• Screw the body/front cover assembly by hand onto the inlet cover.

Important! Make sure that the rotor (C) does not get caught between the seat (B) and the driving tube (E).

• Gently tighten with a wrench. You do not need to tighten too strong. In fact, all operations of disassembling and
reassembling have to be made in the same way, a too strong and too often tightening risks to wear out the
thread and to tear it out when pressurizing.

5. Precautions during work breaks

• Think to protect the rotating nozzle when pausing work to prevent that dirt enters in the body of the nozzle. The
necessary play between rotor and seat is sufficient to let enter different particles of dirt which considerably
shortens the life span of the nozzle
• Do not put the lance on the floor in the water.
• Never put the lance against a dripping wall.

64
65
ORBITAL ROTATING NOZZLE SAFETY INSTRUCTIONS

1. Training:
• It is essential that only properly trained personnel work with UHP water jetting tools.
• The personnel must receive proper training from their employer according to local regulations and they must be
informed of the dangers involved when handling UHP water jetting tools.

2. Precautionary measures in case of danger

• Should a dangerous situation arise, precautionary measures must be established to ensure immediate action to
protect the personnel working with the jetting equipment.
• Take into account the rather unusual dangers involved with an injury. The doctor must be informed through
appropriate means (e.g. the water jet operator should carry a card) that the injury was caused from working
with water jetting tools. The blood can be bacterially infected and must be examined.

3. Manually operated water jetting installations

• The work area of the nozzle operator must be appropriate for working with UHP water jetting tools. Working on
ladders with UHP water jetting tools is not allowed.
• The reaction forces should not exceed 250 N along the longitudinal axis.
• The working pressure should not exceed the pressure engraved on the nozzle body.
• The trigger mechanism of manually operated water jetting installations should not be locked in the on position.

4. Injury prevention
• Ear defenders and protective suits should be worn when working within 10 meters of the water jet.

5. General rules of safety

• Observe the rules of your country for the use of water jetting tools.

66
ULTRA IMPACT NOZZLE SPARE-PARTS ASSEMBLY (OPTIONAL)

67
ULTRA IMPACT NOZZLE SPARE-PARTS LIST (OPTIONAL)

POS. ITEM NO. DESCRIPTION QTY. POS. ITEM NO. QTY. DESCRIPTION
ULTRA IMPACT ROTATING NOZZLE 25 CJL90N0143 INLET SEAL HOUSING 1
* CJL90N0300 *
(Excluding POS. 3 nozzles) 26 CJL90N0131 COMPRESSION SPRING 1
1 CJL90N0248 BOLT 1 27 CJL90N0141 H.P SEAL 1
2 CJL90N0299 SHIELD 1 28 CJL90N0196 SEAL RETAINER 1
3 CJL90M4550 JET NOZZLES (SET OF FOUR) 1 29 CJL90N0137 CARBIDE SEAT 1
4 CJL90N0290 HEAD 1 30 CJL90N0124 RETAINING HOUSING 1
5 CJL90N0291 STUB SHAFT 1 31 CJL90G0162 GLAND NUT COLLAR 1 1/8’’ 1
6 CJL90N0103 BACKUP RING 1 32 CJL90G0161 GLAND NUT 9/16’’ 1
7 CJL90N0192 O-RING 1
8 CJL90N0188 PORT SCREW 1
9 CJL90N0159 CAP 1
10 CJL90N0165 SHAFT SEAL 1
11 CJL90N0134 BEARING 2
12 CJL90N0123 SHAFT 1
13 CJL90N0155 O-RING 1
14 CJL30831 CARTRIDGE ASSY 1
15 CJL90N0147 BODY 1
16 CJL90N0119 O-RING 1
17 CJL90N0106 SHAFT SEAL 1
18 CJL90N0126 BEARING 1
19 CJL90N0181 WASHER 1
20 CJL90N0144 SLEEVE 1
21 CJL90N0186 GARTER SPRING 2
22 CJL90N0198 WEIGHTS 1
23 CJL90N0171 SPRING 1
24 CJL90N0139 SNAP FIT HOUSING 1

68
ULTRA-IMPACT NOZZLE MAINTENANCE

Replacing the cartridge assy:

1. Remove the o-ring (CJL90N0155) from the inlet port. It is easiest to push it upward from the round
weep hole.
2. If necessary, use two picks inserted through the slots to pry the cartridge assy up and out of the
body.
3. Turn the swivel inlet end up; insert a fresh cartridge assy into the inlet port and re-insert the o-ring
behind the cartridge assy to secure it in place.

NOTE: When replacing the cartridge, inspect the end of the shaft in the swivel for damage such as galling
or erosion. Combijet recommends replacing damaged shafts. All kits include either the complete new
cartridge or all the parts needed or all the parts needed to rebuild the cartridge.

POS. ITEM NO. DESCRIPTION QTY.

1 CJL90N0155 O-RING 1
2 CJL30831 CARTRIDGE ASSY 1
3 CJ20120295 SYRINGE 1
4 CJL90N0188 PORT SCREW 1

69
ULTRA IMPACT NOZZLE MAINTENANCE

ULTRA IMPACT NOZZLE MAINTENANCE PROCEDURE & SPARE PARTS LIST

POS. ITEM NO. DESCRIPTION QTY.

1 CJ20120295 SYRINGE FOR ULTRA IMPACT NOZZLE 1
2 CJ20120445 OIL 1 LTR

NOTES: Recommended oil change / refill every 20 to 40 hours of operation.

Do NOT operate the Ultra Impact Nozzle without oil.

70
ULTRA IMPACT NOZZLE TROUBLESHOOTING

Troubleshooting
High pressure seal leak: If water is coming out of the single round hole in the body, it is the inlet connection that
is leaking. If water is coming out of the slots in the body, it is the high-pressure seal that is leaking. Remove the
tool from the gun and remove the O-ring (CJL90N0155) that holds in the cartridge. Replace the cartridge. A
slight drip to small stream leakage may be present from the cartridge while the tool reaches pressure, this leak
may gradually become present over time. This leakage is considered normal and should be eliminated when the
tool reaches the full operating pressure as the dump or pressure shut-off mechanism is engaged.

Seals wear out quickly: Remove and inspect the cartridge parts. The carbide seat should be checked for chips
or erosion parts on it. When the life of the high-pressure seal becomes noticeably less, the seal retainer needs
to be replaced. Also replace the carbide seat if it has not been replaced with each seal change. Very rarely, the
spring that controls the speed of the tool will break, allowing the tool to spin too fast and quickly wear out the
seal

Will not rotate: Check the nozzles to see if they are plugged or partially plugged. To clean them, they must be
removed from the head; it does not do any good to poke the material plugging the nozzle back into the head.
Check that the nozzles are the correct size based on the table given in previous page. If all of these things appear
to be correct, the tool may need to be disassembled and repaired. If the tool has just been rebuilt, and the tool
starts to spin but stops as pressure is increased, the bearings (CJL90N0134) are installed backwards and the tool
must be disassembled and fixed.

71
1