Pulsejet Service - Replacement

Introduction

Use this procedure to replace the following Pulsejet components in the field:

93-30-12599 Pulsejet nozzle assembly
93-30-12603 PulseJet solenoid assembly
93-30-12600 PulseJet tank assembly

Note: If installing the PulseJet option for the first time, do not use this document. Refer to Pulsejet - Installation procedure.

Nozzle Replacement

1

To remove the pulsejet nozzle:

Disconnect the air and oil lines.
Note: Inspect the lines for damage or kinks, and replace them if necessary.
Loosen the clamp screw [1] and slide the PulseJet nozzle out of the P-COOL nozzle.
Important: Support the P-COOL nozzle while you loosen the clamp screw.

Unpack the PulseJet nozzle assembly.

Loosen the clamp screw [1] and slide the clamp and the PulseJet assembly onto the P-COOL nozzle.
Important: Support the P-COOL nozzle while you tighten the clamp screw.
Adjust the PulseJet nozzle so that the oil inlet fitting [2] is on the bottom.
Aim the nozzle approximately at the spindle centerline (it will be adjusted later).

Tighten the clamp set screw.

Find the 1/4” black air line [3] and connect it to the air fitting on the nozzle assembly.
Find the 5/32” clear oil line [4] connect it to the oil fitting.

Command 10-20 pulses until oil is properly streaming out of the nozzle.

Note: If you are only replacing the nozzle (and not the tank) you do not need to run a full priming cycle.

Solenoid Replacement

1

Turn off air to the machine.

Locate the PulseJet solenoid [1].

Disconnect the two air lines [2,3] from the solenoid.

Important: Mark the position of the two air lines, they will need to be installed in the same position.

Disconnect the solenoid cable from the connector bracket.

Remove the old solenoid and install the new one.

Connect the air lines to the solenoid.

Note: The 1/4" clear line [2] attahced to the port with an orifice. The 1/4" black line [3] connects to the port with no orifice.

Connect the solenoid cable to the connector panel labeled "PULSEJET".

Turn on the incoming air and test the PulseJet.

Tank Replacement

1

Locate the tank [1] assembly on the side of the machine.

Place a large container [2] to drain the oil (at least 3 quarts).

Note: if you plan to re-use the oil, the container must be thoroughly cleaned.

Open the valve [3] to let it completely drain. Loosen the tank cap to speed up the draining.

Once the oil is drained, close the drain valve.

Carefully lift the magnetic tank off the machine using a tilting motion. Turn the tank so that you can access the rear of the tank.

Carefully disconnect the air line [4] and oil level sensor [5].

Disconnect the oil line [6].

Note: Oil may flow back through the line, so have a container to place the line in to catch the oil.

2

Connect the 5/32" oil line [1], level sensor cable [2] and the 1/4" tank air line (see diagram).

Carefully install the tank to the side of the machine with the magnets.

Make sure the drain valve [4] is closed.

Open the tank cap and re-fill the tank with oil. Firmly replace cap until it “clicks”.

There will be air trapped inside the system from disconnecting and reconnecting the oil line. This air must be purged out before PulseJet can be used effectively.

Refer to the Prime the Oil Line section in this document.

Prime the Oil Line

Make sure there is oil in the PulseJet reservoir and that the lid is tightly installed. Make sure the reservoir air and oil lines are connected.

Disconnect the oil line [1] from the PulseJet nozzle and let it drape over a container placed on the mill table.

Press [DIAGNOSTIC] and navigate to the Maintanance then to the PulseJet tab [2].

Press [F4] to begin a priming cycle. Each cycle lasts 10 minutes. The reservoir will be pressurized during the cycle.

Note: Small machines may take only 1 cycle to fully prime the line. Larger machines may take 3 or 4 cycles. Heavier oils may take longer to prime. Continue running priming cycles until oil [4] begins to drip out of the oil line into the container.

Note: While the machine is in the prime cycle the user can start a program. However the user will not be able to start the prime cycle again while the program is running.

Reconnect the oil line to the PulseJet nozzle.

In MDI run:

M162 P10;
G04 P10.;
M30;

Test the PulseJet until a strong stream develops.

Tips and Troubleshooting

1. PulseJet will produce a consistent, fast, and tight oil pulse if the line is well primed, the dispenser needle is not clogged, and a recommended oil is being used.

2. To always keep the line well primed:

Place the reservoir assembly near or above the spindle elevation
never let the tank run completely dry

3. If you suspect that the dispenser needle is clogged, replace it. To do this, unscrew the knurled nozzle cap from the nozzle and gently twist and pull the yellow base of the needle off of the nozzle.

Note: This will expose the small check valve spring, do not lose it. Firmly press the replacement needle onto the nozzle taper. Re-install the nozzle cap finger tight.

4. Use recommended oil: light viscosity oils and tapping or cutting fluids work the best. Heavy viscosity oils such as motor oil, gear oil, or heavy tapping oils may not produce a high-quality stream.

5. If the oil line does get air bubbles inside, the pump inside the PulseJet nozzle will pass them through the system. While bubbles are moving through the nozzle, the stream will appear weak, aerated, and inconsistent. After the bubbles pass through, the stream will return to its proper form.

6. Always make sure the reservoir cap is installed and tightened when running PulseJet to maintain the proper tank pressure.

PulseJet Lubrication

Refer to Lubricant Grease, and Sealant Table to see our recommended oil list.