Hypertherm - Cut with Confidence

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  1. Always make sure 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.
    • Always make sure 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 7/8" and 3/4" wrench.

  2. Unthread the hydraulic hose from the hydraulic fitting.
    • Unthread the hydraulic hose from the hydraulic fitting.

    • Loosen the 1/4" gland nut from the side inlet of the valve body.

    • Unthread the 1/4" gland nut from the side inlet of the valve body.

    • Clean the 3/8" gland nut of all Blue Goop with isopropyl alcohol.

    • Loosen the 3/8" high-pressure gland from the outlet adapter using 13/16" and 1" wrench.

    • Unthread the 3/8" high-pressure gland from the outlet adapter.

    • Clean the 3/8" gland nut of all Blue Goop with isopropyl alcohol.

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

    • Unthread the hydraulic fitting from the adapter fitting.

    • Apply an O-ring lubricant to the O-ring from the kit for the hydraulic fitting.

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

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

    • 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.

    • Loosen the actuator housing from the valve body using 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.

    • Discard the O-ring and back-up ring from the piston.

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

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

    • Slide the new back-up ring (flat) into the groove of the piston.

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

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

    • Put the piston assembly into the actuator housing and push with the included dowel.

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

    • Unthread the outlet fitting from the bleed down valve body.

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

    • Remove theflow reducer from the outlet adapter.

    • Clean the outlet adapter and the flow reducer of all Blue Goop with isopropyl alcohol.

    • Loosen the back-up screw from the top of the bleed down valve body using a 5/16" socket wrench.

    • Unthread the seal back-up screw from the top of the bleed down valve body.

    • Clean the seal back-up screw with isopropyl alcohol.

    • Push the components through the bleed down valve body with the included dowel.

    • Clean the bleed down valve body with isopropyl alcohol or a similar cleaning agent.

    • Apply ahigh vacuum grease to the needle.

    • Slide the back-up screw on to the needle so the flat end of the needle is flush with the non threaded part of the back-up screw.

    • Slide the bushing onto the point of the needle with the chamfered end towards the back-up screw.

    • Put the hoop onto the high-pressure seal with the tapered end towards the high-pressure seal and opposite from the O-ring.

    • Put the high-pressure seal assembly onto the point of the needle with the hoop, first.

    • Apply a high vacuum grease to the exterior of the high-pressure seal, hoop, and bushing.

    • Apply a high vacuum grease to the internal threads of the bleed down valve body.

    • Put the high-pressure needle assembly into the top of the bleed down valve body with the point first.

    • Push the seal back-up screw inside of the valve body until it bottoms out.

    • Take the seal back-up screw out of the body and apply a layer of Blue Goop to the threads.

    • Thread in the back-up screw into the top of the bleed down valve body.

    • Tighten the back-up screw to the top of the bleed down valve body using a 5/16" socket wrench.

    • Put the flow reducer into the hole beneath the seat cavity in the outlet adapter.

    • Apply a layer of Blue Goop to the external threads and the seat cavity of the outlet adapter.

    • Put the poppet seat into the seat cavity of the outlet adapter.

    • Apply a layer of Blue Goop to the top of the poppet seat that is sitting in the outlet adapter.

    • Thread the outlet adapter into the valve body.

    • Using a 1" wrench on the outlet adapter and a 7/8" wrench on the valve body, tighten together securely.

    • Apply a layer of Blue Goop to the external threads of the valve body.

    • Thread the actuator housing onto the valve body.

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

    • Apply Blue Goop to the 3/8" gland nut threads.

    • Thread the 3/8" gland nut with the high-pressure tubing into the bleed down valve adapter.

    • Tighten the gland nut into the bleed down valve adapter using 13/16" and 5/8" wrench.

    • Apply Blue Goop to the 1/4" gland nut threads.

    • Thread the 1/4" gland nut into the side of the bleed down valve body.

    • Tighten the gland nut to the side of the bleed down valve body using 3/4" and 5/8" wrench

    • 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 fitting into the hydraulic adapter.

    • Tighten the hydraulic fitting into the hydraulic adapter.

    • Thread the hydraulic hose onto the hydraulic fitting.

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

    • Turn the pump ON and continue the cutting process.

Finish Line

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Adam Dumas

Member since: 05/20/2013

36 Guides authored

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