How to Repair High-Pressure Seals on a Hypertherm Pump Using Kit #11451

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.

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

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.

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.

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.

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.

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.

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.

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 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 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.

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.

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.

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.

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.

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.

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.