Hypertherm - Cut with Confidence

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Always make sure all high-pressure water has been removed from the valve by the following machine manufacturers' safety instructions. Failure to do so can cause severe injury or death. Turn OFF all water pressure to the on/off valve.
  • Always make sure all high-pressure water has been removed from the valve by the following machine manufacturers' safety instructions. Failure to do so can cause severe injury or death.

  • Turn OFF all water pressure to the on/off valve.

  • The valve components can be replaced with the valve body mounted to pump.

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Loosen the high-pressure tubing from the high-pressure gland fitting using a 5/8" and 1" wrench. Unthread the high-pressure tubing from the high-pressure gland fitting. Loosen the high-pressure gland fitting using a 1" wrench.
  • Loosen the high-pressure tubing from the high-pressure gland fitting using a 5/8" and 1" wrench.

  • Unthread the high-pressure tubing from the high-pressure gland fitting.

  • Loosen the high-pressure gland fitting using a 1" wrench.

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Unthread the high-pressure gland fitting from the valve body. Disconnect the air line from the actuator. Unthread the actuator from the valve body.
  • Unthread the high-pressure gland fitting from the valve body.

  • Disconnect the air line from the actuator.

  • Unthread the actuator from the valve body.

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Clean the actuator threads of all Blue Goop with isopropyl alcohol or a similar cleaning agent. Loosen the cap to the actuator with a spanner wrench and a 3/4" breaker bar. Put the actuator housing in the soft-jaw vise if necessary.
  • Clean the actuator threads of all Blue Goop with isopropyl alcohol or a similar cleaning agent.

  • Loosen the cap to the actuator with a spanner wrench and a 3/4" breaker bar.

    • Put the actuator housing in the soft-jaw vise if necessary.

  • Unthread the cap from the actuator.

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Remove the largest O-ring from the actuator housing. Push the dowel (included in the kit) through the hole of the threaded nipple onto the actuator housing to remove the piston. Remove the first O-ring from the piston groove.
  • Remove the largest O-ring from the actuator housing.

  • Push the dowel (included in the kit) through the hole of the threaded nipple onto the actuator housing to remove the piston.

  • Remove the first O-ring from the piston groove.

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Remove the second O-ring from the piston groove. Visually inspect the actuator piston for cracks/wear. Clean the actuator cap of all lithium grease.
  • Remove the second O-ring from the piston groove.

  • Visually inspect the actuator piston for cracks/wear.

  • Clean the actuator cap of all lithium grease.

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Clean the piston of all high vacuum lubricant. Apply high vacuum grease to the two smallest O-rings from the kit. Put one O-ring from the kit onto the groove of the piston.
  • Clean the piston of all high vacuum lubricant.

  • Apply high vacuum grease to the two smallest O-rings from the kit.

  • Put one O-ring from the kit onto the groove of the piston.

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Put the other O-ring from the kit onto the second groove of the piston. Push the piston into the actuator housing with the flat side of the piston up until it bottoms out. Apply high vacuum grease to the biggest O-ring from the kit.
  • Put the other O-ring from the kit onto the second groove of the piston.

  • Push the piston into the actuator housing with the flat side of the piston up until it bottoms out.

  • Apply high vacuum grease to the biggest O-ring from the kit.

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Put the O-ring into the groove on the inside of the actuator housing. Apply lithium grease to the threads of the actuator cap. Thread the actuator cap into the actuator housing.
  • Put the O-ring into the groove on the inside of the actuator housing.

  • Apply lithium grease to the threads of the actuator cap.

  • Thread the actuator cap into the actuator housing.

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Tighten the actuator cap to the actuator housing with a spanner wrench and a 3/4" breaker bar. Remove all the valve components from the valve body with the included dowel. Thoroughly clean the interior of the valve body with the isopropyl alcohol or a similar cleaning agent before replacing the components.
  • Tighten the actuator cap to the actuator housing with a spanner wrench and a 3/4" breaker bar.

  • Remove all the valve components from the valve body with the included dowel.

  • Thoroughly clean the interior of the valve body with the isopropyl alcohol or a similar cleaning agent before replacing the components.

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Visually inspect the top and bottom of the valve bore for cracks/blemishes. If excessive wear or cracks are visible, replace the valve body. Slide the O-ring on to the point of the valve stem. Slide the stainless steel back-up ring on to the valve stem point with the chamfer side towards the O-ring.
  • Visually inspect the top and bottom of the valve bore for cracks/blemishes. If excessive wear or cracks are visible, replace the valve body.

  • Slide the O-ring on to the point of the valve stem.

  • Slide the stainless steel back-up ring on to the valve stem point with the chamfer side towards the O-ring.

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Slide the bronze back-up ring on to the valve stem point with the chamfer side away from stainless steel back-up ring. Put the hoop on the high-pressure seal with the sharp edge of the hoop towards the seal. Slide the hoop and the high-pressure valve seal on to the valve stem with the hoop towards the brass back-up ring.
  • Slide the bronze back-up ring on to the valve stem point with the chamfer side away from stainless steel back-up ring.

  • Put the hoop on the high-pressure seal with the sharp edge of the hoop towards the seal.

  • Slide the hoop and the high-pressure valve seal on to the valve stem with the hoop towards the brass back-up ring.

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Apply high vacuum grease to the outside diameter of the high-pressure valve seal. Put the point of the valve stem into the valve body. Push the valve stem with the dowel until it bottoms out.
  • Apply high vacuum grease to the outside diameter of the high-pressure valve seal.

  • Put the point of the valve stem into the valve body.

  • Push the valve stem with the dowel until it bottoms out.

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Apply Blue Goop to the actuator threads. Thread (hand tighten) the actuator into the top of the valve body until it bottoms out. Reconnect the air tube to the actuator.
  • Apply Blue Goop to the actuator threads.

  • Thread (hand tighten) the actuator into the top of the valve body until it bottoms out.

  • Reconnect the air tube to the actuator.

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Clean the high-pressure gland fitting of all Blue Goop. Reapply Blue Goop to the threads and to the top of the high-pressure gland fitting. Put the seat into the top of the high-pressure gland fitting with the flat side towards the gland fitting.
  • Clean the high-pressure gland fitting of all Blue Goop.

  • Reapply Blue Goop to the threads and to the top of the high-pressure gland fitting.

  • Put the seat into the top of the high-pressure gland fitting with the flat side towards the gland fitting.

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Apply Blue Goop to the top of the seat. Thread the high-pressure gland fitting into the bottom of the valve body. Tighten the high-pressure gland fitting using a 1-1/8" wrench.
  • Apply Blue Goop to the top of the seat.

  • Thread the high-pressure gland fitting into the bottom of the valve body.

  • Tighten the high-pressure gland fitting using a 1-1/8" wrench.

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Clean the high-pressure tubing threads and cone of all Blue Goop with isopropyl alcohol or a similar cleaning agent. Reapply Blue Goop to the high pressure tubing threads and cone. Thread in the high-pressure tubing to the bottom of the high-pressure gland fitting.
  • Clean the high-pressure tubing threads and cone of all Blue Goop with isopropyl alcohol or a similar cleaning agent.

  • Reapply Blue Goop to the high pressure tubing threads and cone.

  • Thread in the high-pressure tubing to the bottom of the high-pressure gland fitting.

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Tighten the high-pressure tubing to the high-pressure gland fitting using a 5/8" and 1" wrench. Apply water pressure to the valve assembly to verify there are no leaks. Re-install the cutting head and continue the cutting process.
  • Tighten the high-pressure tubing to the high-pressure gland fitting using a 5/8" and 1" wrench.

  • Apply water pressure to the valve assembly to verify there are no leaks.

  • Re-install the cutting head and continue the cutting process.

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Finish Line

One other person completed this guide.

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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