Hypertherm - Cut with Confidence

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

  • Turn OFF all hydraulic and water pressure to the bleed-down valve.

  • Loosen the hydraulic hose from the hydraulic fitting using a 7/8" and 3/4" wrench.

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Unthread the hydraulic hose from the hydraulic fitting. Loosen the gland nut on the high-pressure tubing at the high-pressure inlet port of the bleed-down valve using a 13/16" and 5/8" wrench. Unthread the gland nut from the outlet fitting at the high-pressure inlet port of the bleed-down valve.
  • Unthread the hydraulic hose from the hydraulic fitting.

  • Loosen the gland nut on the high-pressure tubing at the high-pressure inlet port of the bleed-down valve using a 13/16" and 5/8" wrench.

  • Unthread the gland nut from the outlet fitting at the high-pressure inlet port of the bleed-down valve.

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Clean the gland nut of all Blue Goop with isopropyl alcohol or a similar cleaning agent. Loosen the gland nut from the outlet fitting (connected to the valve body) using a 13/16" and 5/8" wrench. Unthread the gland nut from the outlet fitting (connected to the valve body).
  • Clean the gland nut of all Blue Goop with isopropyl alcohol or a similar cleaning agent.

  • Loosen the gland nut from the outlet fitting (connected to the valve body) using a 13/16" and 5/8" wrench.

  • Unthread the gland nut from the outlet fitting (connected to the valve body).

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Clean the gland nut of all the Blue Goop. Loosen the hydraulic fitting from the adapter fitting using a 1-1/4" and 7/8" wrench. Unthread the hydraulic fitting from the  adapter fitting.
  • Clean the gland nut of all the Blue Goop.

  • Loosen the hydraulic fitting from the adapter fitting using a 1-1/4" and 7/8" wrench.

  • Unthread the hydraulic fitting from the adapter fitting.

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Apply an O-ring lubricant to the O-ring from the kit for the hydraulic fitting. Replace the O-ring around the hydraulic fitting with the O-ring from the kit (the smallest O-ring from the kit). Loosen the adapter fitting from the actuator housing using a 1-1/4" and 1-1/16" wrench.
  • Apply an O-ring lubricant to the O-ring from the kit for the hydraulic fitting.

  • Replace the O-ring around the hydraulic fitting with the O-ring from the kit (the smallest O-ring from the kit).

  • Loosen the adapter fitting from the actuator housing using a 1-1/4" and 1-1/16" wrench.

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Unthread the adapter fitting from the  actuator housing. Apply an O-ring lubricant to the largest O-ring from the kit. Replace the O-ring on the adapter fitting with the largest O-ring from the kit.
  • Unthread the adapter fitting from the actuator housing.

  • Apply an O-ring lubricant to the largest O-ring from the kit.

  • Replace the O-ring on the adapter fitting with the largest O-ring from the kit.

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Loosen the actuator housing from the valve body using a 1-1/16" and 7/8" wrench. Unthread the actuator housing from the  valve body. Push the piston out of the actuator housing through the oil port using the included dowel.
  • Loosen the actuator housing from the valve body using a 1-1/16" and 7/8" wrench.

  • Unthread the actuator housing from the valve body.

  • Push the piston out of the actuator housing through the oil port using the included dowel.

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Discard the O-ring and the back-up ring from the piston. Inspect the piston, if damage is visible, replace. Apply an O-ring lubricant to cover all of the O-ring and the back-up ring.
  • Discard the O-ring and the back-up ring from the piston.

  • Inspect the piston, if damage is visible, replace.

  • Apply an O-ring lubricant to cover all of the O-ring and the back-up ring.

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Slide the new back-up ring (flat) to the groove of the piston. Slide the new O-ring (rounded) to the  groove of the piston. Make sure the concave side of the back-up ring is towards the O-ring.
  • Slide the new back-up ring (flat) to the groove of the piston.

  • Slide the new O-ring (rounded) to the groove of the piston.

    • Make sure the concave side of the back-up ring is towards the O-ring.

  • Put the piston assembly into the actuator housing the the groove side first and push the piston with the included dowel until the piston bottoms out.

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Loosen the 3/8" to 1/4" adapter from the outlet fitting using a 7/8" and 13/16" wrench. Unthread the 3/8" to 1/4" adapter from the outlet fitting. Loosen the outlet fitting from the bleed down valve body using a 7/8" and 13/16" wrench.
  • Loosen the 3/8" to 1/4" adapter from the outlet fitting using a 7/8" and 13/16" wrench.

  • Unthread the 3/8" to 1/4" adapter from the outlet fitting.

  • Loosen the outlet fitting from the bleed down valve body using a 7/8" and 13/16" wrench.

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Unthread the outlet fitting from the bleed down valve body. Remove the high-pressure seat from the bleed down valve body. Remove the flow reducer from the outlet adapter.
  • Unthread the outlet fitting from the bleed down valve body.

  • Remove the high-pressure seat from the bleed down valve body.

  • Remove the flow reducer from the outlet adapter.

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Clean the outlet adapter of all the Blue Goop. Clean the high-pressure seat of all the Blue Goop. With the bleed down valve tool push through the bleed-down valve body to remove all components.
  • Clean the outlet adapter of all the Blue Goop.

  • Clean the high-pressure seat of all the Blue Goop.

  • With the bleed down valve tool push through the bleed-down valve body to remove all components.

    • The oil seal can also be removed by the bleed down valve tool.

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Thoroughly clean the valve body before replacing the components. Visually inspect the top/bottom of the valve body, if excessive wear or cracks are visible, replace the valve body. Put the high-pressure seal on to the bleed-down valve tool with the O-ring towards the bleed down valve tool.
  • Thoroughly clean the valve body before replacing the components.

  • Visually inspect the top/bottom of the valve body, if excessive wear or cracks are visible, replace the valve body.

  • Put the high-pressure seal on to the bleed-down valve tool with the O-ring towards the bleed down valve tool.

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Slide the hoop, with the sharp edge first, on to the bleed-down valve tool behind the high-pressure seal. Slide the bushing on the bleed-down valve tool with the chamfer side away from the hoop. Apply a high-pressure lubricant to the high-pressure seal, hoop, and bushing.
  • Slide the hoop, with the sharp edge first, on to the bleed-down valve tool behind the high-pressure seal.

  • Slide the bushing on the bleed-down valve tool with the chamfer side away from the hoop.

  • Apply a high-pressure lubricant to the high-pressure seal, hoop, and bushing.

    • The O-ring on the high-pressure seal can pinch or strip when installing into the valve body.

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Put the bleed-down valve tool with the parts into the bottom of the valve body until the tool reaches the bottom of the valve. Be aware that the inner diameter of the valve body has a small step, it can pinch or strip the O-ring from the high-pressure seal during installation. Apply a high-pressure lubricant to the stem.
  • Put the bleed-down valve tool with the parts into the bottom of the valve body until the tool reaches the bottom of the valve.

    • Be aware that the inner diameter of the valve body has a small step, it can pinch or strip the O-ring from the high-pressure seal during installation.

  • Apply a high-pressure lubricant to the stem.

  • Replace the oil seal, place on the top of the valve body.

    • Put the concave (rubber) side down towards the valve body.

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Put the stem through the high-pressure seal until it is flush with the oil seal. Apply Blue Goop to all surfaces of the high-pressure seat. Put the high-pressure seat at the bottom of the bleed-down valve body with the pointed end out.
  • Put the stem through the high-pressure seal until it is flush with the oil seal.

  • Apply Blue Goop to all surfaces of the high-pressure seat.

  • Put the high-pressure seat at the bottom of the bleed-down valve body with the pointed end out.

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Apply Blue Goop to the outlet adapter threads. Put the flow reducer in the outlet adapter. Thread the outlet adapter into the valve body.
  • Apply Blue Goop to the outlet adapter threads.

  • Put the flow reducer in the outlet adapter.

  • Thread the outlet adapter into the valve body.

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Tighten the outlet adapter to the valve body using a 7/8" and 13/16" wrench. Thread the 3/8" to 1/4" adapter to the outlet adapter. Tighten the 3/8" to 1/4" adapter to the  outlet adapter using a 7/8" and 13/16" wrench.
  • Tighten the outlet adapter to the valve body using a 7/8" and 13/16" wrench.

  • Thread the 3/8" to 1/4" adapter to the outlet adapter.

  • Tighten the 3/8" to 1/4" adapter to the outlet adapter using a 7/8" and 13/16" wrench.

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Apply Blue Goop to the top threads of the valve body. With the piston assembly installed, thread the actuator housing onto the valve body. Tighten the actuator housing to the  valve body using 1-1/16" and 7/8" wrench.
  • Apply Blue Goop to the top threads of the valve body.

  • With the piston assembly installed, thread the actuator housing onto the valve body.

  • Tighten the actuator housing to the valve body using 1-1/16" and 7/8" wrench.

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Thread the adapter fitting into the actuator housing. Tighten the adapter fitting into the actuator housing using 1-1/4" and 1-1/16" wrench Thread the hydraulic adapter into the adapter fitting.
  • Thread the adapter fitting into the actuator housing.

  • Tighten the adapter fitting into the actuator housing using 1-1/4" and 1-1/16" wrench

  • Thread the hydraulic adapter into the adapter fitting.

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Tighten the hydraulic fitting into the adapter fitting using 1-1/4" and 7/8" wrench. Apply Blue Goop to the threads of the gland nut. Thread the gland nut into the outlet fitting (connected to the valve body).
  • Tighten the hydraulic fitting into the adapter fitting using 1-1/4" and 7/8" wrench.

  • Apply Blue Goop to the threads of the gland nut.

  • Thread the gland nut into the outlet fitting (connected to the valve body).

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Tighten the gland nut to the outlet fitting (connected to the valve body) using 13/16" and 5/8" wrench. Apply Blue Goop to the gland nut threads. Thread the gland nut into the outlet fitting (connected to the collar).
  • Tighten the gland nut to the outlet fitting (connected to the valve body) using 13/16" and 5/8" wrench.

  • Apply Blue Goop to the gland nut threads.

  • Thread the gland nut into the outlet fitting (connected to the collar).

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Tighten the gland nut into the outlet fitting (connected to the collar) using a 13/16" and 5/8" wrench. Thread the hydraulic hose on to the hydraulic fitting. Tighten the hydraulic hose to the hydraulic fitting using a 7/8" and 3/4" wrench.
  • Tighten the gland nut into the outlet fitting (connected to the collar) using a 13/16" and 5/8" wrench.

  • Thread the hydraulic hose on to the hydraulic fitting.

  • Tighten the hydraulic hose to the hydraulic fitting using a 7/8" and 3/4" wrench.

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Turn the pump ON and continue the cutting process.
  • Turn the pump ON and continue the cutting process.

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Finish Line

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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