Hypertherm - Cut with Confidence

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  1. 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.
    • 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.

  2. Loosen the high-pressure tubing from the high-pressure gland fitting using a 5/8" and 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.

    • Unthread the high-pressure gland fitting from the valve body.

    • Disconnect the air line from the actuator.

    • Unthread the actuator from the valve body.

    • 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.

    • 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 second O-ring from the piston groove.

    • Visually inspect the actuator piston for cracks/wear.

    • Clean the actuator cap of all lithium grease.

    • 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.

    • 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 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.

    • 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.

    • 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.

    • 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.

    • 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 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.

    • 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.

    • 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.

    • 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.

    • 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.

Finish Line

One other person completed this guide.

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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