Attenuator guard
for 100-hp, 125-hp, and 150-hp pumps and 60-hp and 75-hp
pumps with redundant intensifiers
Installation guide
809640 | Revision 0 | English
HyPrecision and Hypertherm are trademarks of Hypertherm Inc. and may be registered in the United States and other
countries. All other trademarks are the property of their respective holders.
© 2016 Hypertherm Inc.
Attenuator guard
Installation guide
809640
Revision 0
English
Original Instructions
June 2016
Hypertherm Inc.
Hanover, NH 03755 USA
www.hypertherm.com
Hypertherm Inc.
Etna Road, P.O. Box 5010
Hanover, NH 03755 USA
603-643-3441 Tel (Main Office)
603-643-5352 Fax (All Departments)
info@hypertherm.com (Main Office Email)
800-643-9878 Tel (Technical Service)
technical.service@hypertherm.com (Technical Service Email)
800-737-2978 Tel (Customer Service)
customer.service@hypertherm.com (Customer Service Email)
866-643-7711 Tel (Return Materials Authorization)
877-371-2876 Fax (Return Materials Authorization)
return.materials@hypertherm.com (RMA email)
Hypertherm México, S.A. de C.V.
Avenida Toluca No. 444, Anexo 1,
Colonia Olivar de los Padres
Delegación Álvaro Obregón
México, D.F. C.P. 01780
52 55 5681 8109 Tel
52 55 5683 2127 Fax
Soporte.Tecnico@hypertherm.com (Technical Service Email)
Hypertherm Plasmatechnik GmbH
Sophie-Scholl-Platz 5
63452 Hanau
Germany
00 800 33 24 97 37 Tel
00 800 49 73 73 29 Fax
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
technicalservice.emea@hypertherm.com (Technical Service Email)
Hypertherm (Singapore) Pte Ltd.
82 Genting Lane
Media Centre
Annexe Block #A01-01
Singapore 349567, Republic of Singapore
65 6841 2489 Tel
65 6841 2490 Fax
Marketing.asia@hypertherm.com (Marketing Email)
TechSupportAPAC@hypertherm.com (Technical Service Email)
Hypertherm Japan Ltd.
Level 9, Edobori Center Building
2-1-1 Edobori, Nishi-ku
Osaka 550-0002 Japan
81 6 6225 1183 Tel
81 6 6225 1184 Fax
HTJapan.info@hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com (Technical Service Email)
Hypertherm Europe B.V.
Vaartveld 9, 4704 SE
Roosendaal, Nederland
31 165 596907 Tel
31 165 596901 Fax
31 165 596908 Tel (Marketing)
31 (0) 165 596900 Tel (Technical Service)
00 800 4973 7843 Tel (Technical Service)
technicalservice.emea@hypertherm.com
(Technical Service Email)
Hypertherm (Shanghai) Trading Co., Ltd.
B301, 495 ShangZhong Road
Shanghai, 200231
PR China
86-21-80231122 Tel
86-21-80231120 Fax
86-21-80231128 Tel (Technical Service)
techsupport.china@hypertherm.com
(Technical Service Email)
South America & Central America: Hypertherm Brasil Ltda.
Rua Bras Cubas, 231 – Jardim Maia
Guarulhos, SP – Brasil
CEP 07115-030
55 11 2409 2636 Tel
tecnico.sa@hypertherm.com (Technical Service Email)
Hypertherm Korea Branch
#3904. APEC-ro 17. Heaundae-gu. Busan.
Korea 48060
82 (0)51 747 0358 Tel
82 (0)51 701 0358 Fax
Marketing.korea@hypertherm.com (Marketing Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
Hypertherm Pty Limited
GPO Box 4836
Sydney NSW 2001, Australia
61 (0) 437 606 995 Tel
61 7 3219 9010 Fax
au.sales@Hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
Hypertherm (India) Thermal Cutting Pvt. Ltd
A-18 / B-1 Extension,
Mohan Co-Operative Industrial Estate,
Mathura Road, New Delhi 110044, India
91-11-40521201/ 2/ 3 Tel
91-11 40521204 Fax
HTIndia.info@hypertherm.com (Main Office Email)
TechSupportAPAC@hypertherm.com
(Technical Service Email)
1/28/16
Information and hazard symbols
Some symbols in this table could be relevant to other products.
This symbol identifies an imminently hazardous situation, which, if not avoided, will result in
DANGER
DANGER
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death or serious injury.
Dangerous voltage
To reduce the risk of serious injuries or death, wear approved protection and follow safety
recommendations when working with electricity.
This symbol identifies a potentially hazardous situation, which, if not avoided, could result in
death or serious injury.
Do not operate this equipment without the guard installed
Symbols and marks
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CAUTION
Risk of explosion
This symbol identifies a potentially hazardous situation, which, if not avoided, could result in
minor or moderate injury, or property damage.
Refer to the instruction manual. Read and understand all of the safety guidelines in this manual.
This symbol identifies a mandatory action.
This symbol identifies a prohibited action.
This symbol identifies tools or materials that are required or recommended for a procedure.
This symbol identifies a note or helpful information.
Safety and compliance Installation guide 809640 SC-5
Symbols and marks
SC-6 Safety and compliance Installation guide 809640
Section 1
Product description
This guard is designed to be used on a 2-liter Hypertherm or AccuStream attenuator.
The attenuator guard is intended to keep personnel safe from studs or end caps, which can become projectiles if the
attenuator fails.
Specifications
2-liter attenuator
Attenuator guard
181.44 kg (400 lb)
99.06 cm × 22.2 cm × 18.26 cm (39 in × 8-3/4 in × 7-3/16 in)
25.85 kg (57 lb)
Attenuator guard Installation guide 809640 7
Product description
8 Attenuator guard Installation guide 809640
Section 2
Installation
Hypertherm products are designed and manufactured with a commitment to continuous quality control and safety.
Contact a Hypertherm Technical Service Associate for information and support regarding the installation and repair of
this equipment.
These installation instructions are for 2-liter attenuators installed on:
HyPrecision models 150D, 100D, 75S with redundant intensifiers, and 60S with redundant intensifiers
AccuStream models AS-6075, AS-60100, AS-60125, and AS-60150
For 60-hp and 75-hp models with single intensifiers, refer to 809630 At
and 75-hp pumps with single intensifiers.
For models not identified here, contact a Hyperthe
rm Technical Service Associate.
Safety
Refer to the instruction manual. Read and understand all of the safety guidelines in this manual.
Dangerous voltage
To reduce the risk of serious injuries or death, wear approved protection and follow safety
DANG ER
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WAR NING
recommendations when working with electricity.
Personal protective equipment is recommended. Failure to wear personal protective equipment can result
in injuries or death.
A person who works on deenergized machinery may be seriously injured or killed if the machinery is
reenergized without permission.
All workers must respect lock-out and tag-out devices. Only the person who applies a hazardous energy
control device should remove it.
All workers in an area where energy-control procedures are used must receive training regarding the
energy-control procedure and the prohibition against removing a lock-out or tag-out device.
tenuator guard installation guide for 60-hp
Keep the work area clean and free of fluid spills.
Attenuator guard Installation guide 809640 9
Installation
Unpack the guard
Make sure that these items are included:
Attenuator guard
Attenuator guard strap kit
The attenuator guard strap kit contains:
2 guard straps
4 adhesive-backed rubber pads
3/8-inch wrench
16323 Attenuator guard installation tool kit
Refer to
16342 High-pressure tubing kit (for model 150D only)
16323 Attenuator guard installation tool kit on page 26 for a list of contents.
Refer to
16342 150D attenuator guard high-pressure tubing kit on page 26 for a list of contents.
Make sure that the equipment was not damaged during shipping. If the equipment is damaged, a claim must be filed
with the carrier. Report shortages or damages to the OEM or to Hypertherm Waterjet within 10 days of receipt of the
equipment.
To install the guard on 125-hp and 100-hp models and 60-hp and 75-hp models with redundant intensifiers, refer to
page 11.
To install the guard on a 150-hp model, refer to page 17.
10 Attenuator guard Installation guide 809640
Installation
1
2
3
3
4
4
1 Attenuator
2 Attenuator straps
3 High-pressure tubing
4 Intensifiers
Install the guard on 125-hp and 100-hp models and 60-hp and 75-hp models with redundant intensifiers
Disconnect and lock out or tag out the electrical main and relieve all water and hydraulic pressure from
WAR NING
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the pump before installing this equipment.
This installation procedure requires 2 people for some tasks.
Required parts, tools, and materials
Attenuator guard Installation guide 809640 11
16320 Attenuator guard strap kit
16323 Attenuator guard installation tool kit
High-pressure antiseize lubricant such as Blue Goop or AccuGoop
13/16-inch open-ended wrench
Crane or forklift
Installation
1
2
1 Covers
2 Bridge
Remove the covers and the bridge from the pump
1. Remove the screws at both ends of the bridge. If there are not screws in the location shown, remove the
outermost hinge screws.
2. Put eye bolts into the bridge screw holes. Put the shackles on the eye bolts. Put a lifting strap through each
3. Use an assistant to hold 1 pump cover open.
12 Attenuator guard Installation guide 809640
shackle.
4. Disconnect the gas shocks from both ends of the cover.
a. Use a small screwdriver to pry the spring-steel retainer off of the end of the shock.
b. Hit the shock with an open hand to release it from the ball.
Installation
5. Remove the mounting bolts at both ends of the bridge.
6. Close the cover.
7. Repeat steps 4 through 7 for the other cover.
Attenuator guard Installation guide 809640 13
Installation
8. Use a forklift or a crane to lift the bridge and covers off of the pump as one unit.
Misuse of lifting equipment could cause the load to become unstable, which can result in property
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damage, personal injury, or death.
Lifting must be done by a trained operator. Follow all of the relevant work site safety requirements, the
safety instructions for the lifting equipment, and the safety information in this guide.
Install the attenuator guard
1. Disconnect the high-pressure tubing from both ends of the attenuator. The tubing and connections are indicated
in red.
2. Put the adhesive-backed rubber pads on the tabs on both ends of the attenuator guard.
3. Use an assistant to help put the guard over the attenuator.
14 Attenuator guard Installation guide 809640
Install the guard straps
1. Put the guard straps inside the guard and around the attenuator.
2. Put the ends of the guard straps into the bolt drives.
Installation
3. Put the guard straps over the tabs on the top of the attenuator guard.
4. Turn the bolt drives clockwise to tighten the guard straps.
Attenuator guard Installation guide 809640 15
Installation
Assemble the pump
1. Connect the high-pressure tubing to the attenuator. Torque the connectors to 68 N ∙ m (50 lbf ∙ ft).
Put high-pressure antiseize lubricant on the threads of all high-pressure connectors.
2. Replace the bridge and covers on the pump with a forklift or a crane.
3. Use an assistant to hold 1 pump cover open.
4. Install the mounting bolts on each end of the bridge.
5. Reconnect the gas shocks.
a. Hit the shock with an open hand to set it on the ball.
b. Install the spring-steel retainer.
6. Repeat steps 3 through 5 for the other cover.
7. Remove the eye bolts and replace the screws in the bridge or the hinge.
8. Turn ON the pump in cooling mode. Monitor for leaks. Identify the source of a leak and repair the problem.
Use a piece of cardboard or other solid material to find leaks when the pump is operating. Do not
WAR N ING
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use hands, cloth, paper, or towels.
Do not repair a leak with high-pressure water in the system. Discharge all high-pressure water
before working on this equipment.
16 Attenuator guard Installation guide 809640
1
5
4
4
6
9
8
2
3
7
6
Install the guard on a 150-hp model
1 Attenuator
2 Left end
3 Right end
4 High-pressure tubing
5 Attenuator straps
6 Low-pressure hoses
7 Tee connector
8 Access hole
9 Intensifiers
Disconnect and lock out or tag out the electrical main and relieve all water and hydraulic pressure from
WAR NING
WAR NING
the pump before installing this equipment.
This installation procedure requires 2 people for some tasks.
Installation
Required parts, tools, and materials
16320 Attenuator guard strap kit
16323 Attenuator guard installation tool kit
16342 High-pressure tubing kit
High-pressure antiseize lubricant such as Blue Goop or AccuGoop
13/16-inch open-ended wrench
Crane or forklift
Attenuator guard Installation guide 809640 17
Installation
Remove the attenuator from the pump
1. Remove the attenuator access cover.
2. Disconnect the high-pressure tubing from the right end of the attenuator. The tubing and connections are shown
in red.
It might be necessary to loosen or remove other high-pressure connections.
3. Remove the high-pressure fitting and tubing from the left end of the attenuator. Remove the elbow, the fitting, and
the tubing that connect to the high-pressure tee below the pump ‘s top deck. Dispose of these parts.
18 Attenuator guard Installation guide 809640
Installation
4. Disconnect the low-pressure water hose from both ends of the intensifier. The hoses and connections are shown
in blue.
5. Push the low-pressure hoses and tee connector down through the access hole in the pump's top deck.
6. Remove the 2 attenuator straps.
7. Install an adapter from the 16323 Attenuator guard installation tool kit in the left end of the attenuator. Torque the
adapter to 149.14 N ∙ m (110 lbf ∙ ft).
Put high-pressure antiseize lubricant on the threads of all high-pressure connectors.
8. Lift the attenuator through the attenuator access hole with a forklift or crane.
Misuse of lifting equipment could cause the load to become unstable, which can result in property
WAR NING
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It is recommended that the lifting straps be secured under the 3 top bolts on the attenuator.
damage, personal injury, or death.
Lifting must be done by a trained operator. Follow all of the relevant work site safety requirements, the
safety instructions for the lifting equipment, and the safety information in this guide.
Attenuator guard Installation guide 809640 19
Installation
Install the attenuator guard
1. Put the adhesive-backed rubber pads on the tabs on both ends of the attenuator guard.
2. Use an assistant to help put the guard through the attenuator access hole onto the pump’s top deck.
Put the attenuator guard on its side with the top of the guard toward the intensifiers.
20 Attenuator guard Installation guide 809640
Installation
1 2
1 Attenuator end 2 Support end
3. Put the attenuator onto the attenuator supports.
4. Use the attenuator locating tool from the 16323 Attenuator guard installation tool kit to make sure that the
attenuator is centered on the supports. Line up the notched end of the tool with the flat face of the attenuator
body. The attenuator is centered when the support end of the tool is flat against the attenuator support.
5. Replace the 2 attenuator straps. Tighten the strap bolts.
6. Use an assistant to help put the guard over the attenuator.
Attenuator guard Installation guide 809640 21
Installation
Install the guard straps
1. Put the guard straps inside the guard and around the attenuator.
2. Put the ends of the guard straps into the bolt drives.
3. Put the guard straps over the tabs on the top of the attenuator guard.
4. Turn the bolt drives clockwise to tighten the guard straps.
22 Attenuator guard Installation guide 809640
Installation
1
2
3
1 Tubing assembly
2 Adapter
3 High-pressure tee
Assemble the pump
1. Connect the high-pressure tubing to the right end of the attenuator. Torque the connector to 68 N ∙ m (50 lbf ∙ ft).
Put high-pressure antiseize lubricant on the threads of all high-pressure connectors.
2. Install the high-pressure tubing on the left end of the attenuator.
a. Put the shorter end of the tubing assembly into the adapter in the attenuator (installed on page 19). Torque
the connector to 68 N ∙ m (50 lbf ∙ ft).
b. Install the remaining adapter in the high-pressure tee below the pump’s top deck. Torque the adapter to
149.14 N ∙ m (110 lbf ∙ ft).
3. Retrieve the low-pressure hose assembly from the access hole in the pump's top deck. Connect the low-pressure
Attenuator guard Installation guide 809640 23
c. Put the longer end of the tubing assembly into the adapter in the high-pressure tee. Torque the connector to
68 N ∙ m (50 lbf ∙ ft).
hoses to the intensifier.
Installation
4. Replace the attenuator access cover.
5. Turn ON the pump in cooling mode. Monitor for leaks. Identify the source of a leak and repair the problem.
Use a piece of cardboard or other solid material to find leaks when the pump is operating. Do not
WAR N ING
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use hands, cloth, paper, or towels.
Do not repair a leak with high-pressure water in the system. Discharge all high-pressure water
before working on this equipment.
24 Attenuator guard Installation guide 809640
Section 3
Parts lists
Genuine Hypertherm parts are the factory-recommended replacement parts for this pump. The Hypertherm warranty
might not cover damage caused by using nongenuine Hypertherm parts.
To order parts, contact the original equipment manufacturer (OEM) or Hypertherm Inc. with the part numbers and
quantities.
Hypertherm Waterjet
305 2nd Ave NW, Suite 115
New Brighton, MN 55112 USA
+1 866-566-7099
+1 651-294-8620 fax
Quantity refers to the number of units included with each part number.
16320 2-liter attenuator guard assembly kit
Part number Description Quantity
16308 Guard strap 2
16309 Adhesive-backed rubber pad 4
16322 3/8-inch wrench 1
80963
Attenuator guard installation guide
for 60-hp and 75-hp pumps with single intensifiers
1
Attenuator guard Installation guide 809640 25
Parts lists
16323 Attenuator guard installation tool kit
Not used for 60-hp and 75-hp pumps with single intensifiers
Part number Description Quantity
Attenuator guard installation guide
809640
— 6-foot lifting strap 1
— 5/32-inch hex-head wrench 1
Used only for 125-hp and 100-hp models and 60-hp and 75-hp models with redundant intensifiers
—Flat-blade screwdriver 1
— 1/4-20 eye bolt (rated for 226 kg/500 lb) 2
—Shackle 2
Used only for 150-hp models
for 100-hp, 125-hp, and 150-hp pumps and 60-hp and 75-hp pumps with
redundant intensifiers
1
— Attenuator locating tool 1
— 3/8-inch square-drive socket wrench 1
— 3/8-inch socket extension, 15 in. 1
— 9/16-inch hex socket 1
16342 150D attenuator guard high-pressure tubing kit
Used only for 150-hp models
Part number Description Quantity
16330 3/8-inch high-pressure tubing 1
12580 3/8-inch protective sheathing 1
14687 Protective sheathing end cover 2
13162-60-6F9M 9/16-inch male to 3/8-inch female adapter 2
Other parts
Lubricants
Part number Description
11111 Blue Goop high-pressure antiseize lubricant
11448 AccuGoop food-grade high-pressure antiseize lubricant
26 Attenuator guard Installation guide 809640
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