Hypertherm - Cut with Confidence

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Image 1/2: Turn OFF all water pressure to the on/off valve. Image 2/2: The valve components can be replaced with the [http://www.accustream.com/all-products/11320.html|valve body] mounted to pump.
  • 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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Image 1/3: Unthread the high-pressure tubing from the high-pressure gland fitting. Image 2/3: Loosen the [http://www.accustream.com/all-products/12347.html|high-pressure gland fitting] using a 1" wrench. Image 3/3: Loosen the [http://www.accustream.com/all-products/12347.html|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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Image 1/3: Disconnect the air line from the [http://www.accustream.com/all-products/13243.html|actuator]. Image 2/3: Unthread the actuator from the valve body. Image 3/3: 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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Image 1/3: Loosen the cap to the actuator with a spanner wrench and a 3/4" breaker bar. Image 2/3: Put the actuator housing in the soft-jaw vise if necessary. Image 3/3: Unthread the cap from the actuator.
  • 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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Image 1/3: Push the dowel (included in the kit) through the hole of the threaded nipple onto the actuator housing to remove the piston. Image 2/3: Remove the first O-ring from the piston groove. Image 3/3: 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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Image 1/3: Visually inspect the actuator piston for cracks/wear. Image 2/3: Clean the actuator cap of all lithium grease. Image 3/3: 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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Image 1/3: Apply high vacuum grease to the two smallest O-rings from the kit. Image 2/3: Put one O-ring from the kit onto the groove of the piston. Image 3/3: 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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Image 1/3: Push the piston into the actuator housing with the flat side of the piston up until it bottoms out. Image 2/3: Apply high vacuum grease to the biggest O-ring from the kit. Image 3/3: 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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Image 1/3: Apply lithium grease to the threads of the actuator cap. Image 2/3: Thread the actuator cap into the actuator housing. Image 3/3: 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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Image 1/3: Remove all the valve components from the valve body with the included dowel. Image 2/3: Thoroughly clean the interior of the valve body with the isopropyl alcohol or a similar cleaning agent before replacing the components. Image 3/3: 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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Image 1/3: Slide the [http://www.accustream.com/all-products/11240.html|O-ring] on to the point of the valve stem. Image 2/3: Slide the [http://www.accustream.com/all-products/12733.html|stainless steel back-up ring] on to the valve stem point with the chamfer side towards the O-ring. Image 3/3: Slide the [http://www.accustream.com/all-products/12733.html|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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Image 1/3: Put the [http://www.accustream.com/all-products/14322.html|hoop] on the [http://www.accustream.com/all-products/14322.html|high-pressure seal] with the sharp edge of the hoop towards the seal. Image 2/3: Slide the hoop and the high-pressure valve seal on to the valve stem with the hoop towards the brass back-up ring. Image 3/3: 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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Image 1/3: Put the point of the valve stem into the valve body. Image 2/3: Push the valve stem with the dowel until it bottoms out. Image 3/3: 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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Image 1/3: Thread (hand tighten) the actuator into the top of the valve body until it bottoms out. Image 2/3: Reconnect the air tube to the actuator. Image 3/3: 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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Image 1/3: Reapply Blue Goop to the threads and to the top of the high-pressure gland fitting. Image 2/3: Put the seat into the top of the high-pressure gland fitting with the flat side towards the gland fitting. Image 3/3: 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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Image 1/3: Thread the high-pressure gland fitting into the bottom of the valve body. Image 2/3: Tighten the high-pressure gland fitting using a 1-1/8" wrench. Image 3/3: 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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Image 1/3: Reapply Blue Goop to the high pressure tubing threads and cone. Image 2/3: Thread in the high-pressure tubing to the bottom of the high-pressure gland fitting. Image 3/3: 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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Image 1/3: Apply water pressure to the valve assembly to verify there are no leaks. Image 2/3: Re-install the cutting head and continue the cutting process. Image 3/3: 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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