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Hypertherm - Cut with Confidence

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  1. Loosen the check valve by tapping with a rubber mallet while rolling the cylinder. Remove the check valve from the high-pressure cylinder Remove the low-pressure poppet from the high-pressure cylinder.
  2. Put the high-pressure cylinder onto the locator tool. Put the stepped end of the push tool into the top of the high-pressure cylinder. Hit the push tool with a rubber mallet to push out the high-pressure seal and hoop
    • Put the high-pressure cylinder onto the locator tool.

    • Put the stepped end of the push tool into the top of the high-pressure cylinder.

    • Hit the push tool with a rubber mallet to push out the high-pressure seal and hoop

  3. Remove the hoop and the high-pressure seal assembly from the end of the high-pressure cylinder. Remove the locator tool from the high-pressure cylinder. Flip the high-pressure cylinder and place it onto the locator tool.
    • Remove the hoop and the high-pressure seal assembly from the end of the high-pressure cylinder.

    • Remove the locator tool from the high-pressure cylinder.

    • Flip the high-pressure cylinder and place it onto the locator tool.

  4. Push the spacer tube down until it bottoms out. Put the nonstepped end of the push tool into the high-pressure cylinder. Hit the push tool with a rubber mallet to push the second hoop and the high-pressure seal assembly out of the high-pressure cylinder.
    • Push the spacer tube down until it bottoms out.

    • Put the nonstepped end of the push tool into the high-pressure cylinder.

    • Hit the push tool with a rubber mallet to push the second hoop and the high-pressure seal assembly out of the high-pressure cylinder.

  5. Remove the hoop and high-pressure seal assembly from the high-pressure cylinder. Remove the locator tool from the high-pressure cylinder. Remove the spacer tube and low-pressure poppet basket from the high-pressure cylinder.
    • Remove the hoop and high-pressure seal assembly from the high-pressure cylinder.

    • Remove the locator tool from the high-pressure cylinder.

    • Remove the spacer tube and low-pressure poppet basket from the high-pressure cylinder.

  6. Clean the high-pressure cylinder of all Blue Goop with isopropyl alcohol or a similar cleaning agent. Clean the removal/installation tools with isopropyl alcohol or a similar cleaning agent. Clean the spacer tube, check valve,  low-pressure poppet, and low-pressure poppet basket.
    • Clean the high-pressure cylinder of all Blue Goop with isopropyl alcohol or a similar cleaning agent.

    • Clean the removal/installation tools with isopropyl alcohol or a similar cleaning agent.

    • Clean the spacer tube, check valve, low-pressure poppet, and low-pressure poppet basket.

  7. Roll scouring pad in both ends of the bore of the high-pressure cylinder to remove any blemishes. Clean the high-pressure cylinder once more to remove all excess material from Scotch Brite Put the high-pressure cylinder onto the high-pressure seal installation spacer tool.
    • Roll scouring pad in both ends of the bore of the high-pressure cylinder to remove any blemishes.

    • Clean the high-pressure cylinder once more to remove all excess material from Scotch Brite

    • Put the high-pressure cylinder onto the high-pressure seal installation spacer tool.

  8. Apply a light coat of high vacuum grease to both ends of the spacer tube. Put the low-pressure poppet into the low-pressure poppet basket with the stem of the poppet facing basket. Make sure that the low-pressure poppet moves freely in the low-pressure poppet basket.
    • Apply a light coat of high vacuum grease to both ends of the spacer tube.

    • Put the low-pressure poppet into the low-pressure poppet basket with the stem of the poppet facing basket.

    • Make sure that the low-pressure poppet moves freely in the low-pressure poppet basket.

  9. Put the low-pressure poppet and basket into the spacer tube. Put the spacer tube with the poppet and basket up into the high-pressure cylinder. Put the locator tool onto the high-pressure cylinder.
    • Put the low-pressure poppet and basket into the spacer tube.

    • Put the spacer tube with the poppet and basket up into the high-pressure cylinder.

    • Put the locator tool onto the high-pressure cylinder.

  10. Put the sleeve into the locator tool with the tapered end up. Apply high vacuum grease to the O-rings. Put the O-rings onto the high-pressure seals.
    • Put the sleeve into the locator tool with the tapered end up.

    • Apply high vacuum grease to the O-rings.

    • Put the O-rings onto the high-pressure seals.

  11. Put the high-pressure seal into the sleeve with the O-ring down. Put the non-stepped end of the push tool into the sleeve and press the high-pressure seal into the high-pressure cylinder until it bottoms out. Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the seal.
    • Put the high-pressure seal into the sleeve with the O-ring down.

    • Put the non-stepped end of the push tool into the sleeve and press the high-pressure seal into the high-pressure cylinder until it bottoms out.

    • Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the seal.

    • Put the hoop into the sleeve with the tapered end down towards the high-pressure seal.

  12. Put the non-stepped end of the push tool into the sleeve and be sure that the tool is level with the sleeve. Use a rubber mallet to set the hoop into the high-pressure cylinder (until the push tool bottoms out). Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the hoop.
    • Put the non-stepped end of the push tool into the sleeve and be sure that the tool is level with the sleeve.

    • Use a rubber mallet to set the hoop into the high-pressure cylinder (until the push tool bottoms out).

    • Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the hoop.

    • Remove the installation tools from the top of the high-pressure cylinder.

  13. Put the check valve on the high-pressure cylinder. Use a rubber mallet to tap the check valve into the high-pressure cylinder. Flip the high-pressure cylinder over so the cylinder is resting on the check valve.
    • Put the check valve on the high-pressure cylinder.

    • Use a rubber mallet to tap the check valve into the high-pressure cylinder.

    • Flip the high-pressure cylinder over so the cylinder is resting on the check valve.

  14. Remove the seal installation spacer tool from the end of the high-pressure cylinder. Put the locator tool on the high-pressure cylinder. Put the sleeve into the locator tool with the tapered end up.
    • Remove the seal installation spacer tool from the end of the high-pressure cylinder.

    • Put the locator tool on the high-pressure cylinder.

    • Put the sleeve into the locator tool with the tapered end up.

  15. Put the high-pressure seal into the sleeve with the o-ring down. Put the non-stepped end of the push tool into the sleeve and press the high-pressure seal into the high-pressure cylinder until it bottoms out. Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the seal.
    • Put the high-pressure seal into the sleeve with the o-ring down.

    • Put the non-stepped end of the push tool into the sleeve and press the high-pressure seal into the high-pressure cylinder until it bottoms out.

    • Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the seal.

    • Put the hoop into the sleeve with the tapered end down towards the high-pressure seal.

  16. Put the non-stepped end of the push tool into the sleeve and be sure that the tool is level with the sleeve. Use a rubber mallet to set the hoop into the high-pressure cylinder (until the push tool bottoms out). Hold the sleeve down against the  cylinder with one hand to be sure it doesn't raise up while installing the hoop.
    • Put the non-stepped end of the push tool into the sleeve and be sure that the tool is level with the sleeve.

    • Use a rubber mallet to set the hoop into the high-pressure cylinder (until the push tool bottoms out).

    • Hold the sleeve down against the cylinder with one hand to be sure it doesn't raise up while installing the hoop.

    • Remove the installation tools from the top of the high-pressure cylinder.

  17. Apply Blue Goop to the outer edge of the high-pressure cylinder inset. Continue with the installation with the high-pressure cylinder onto the intensifier.
    • Apply Blue Goop to the outer edge of the high-pressure cylinder inset.

    • Continue with the installation with the high-pressure cylinder onto the intensifier.

Finish Line

19 other people completed this guide.

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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