Hypertherm - Cut with Confidence

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How to Repair a Bleed Down Valve Assembly ll #12981

Written By: Adam Dumas (and 2 other contributors)
  • Comments: 2
  • Favorites: 3
  • Completions: 6

Difficulty

Moderate

Steps

24

Time Required

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

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

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

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

  2. Unthread hose from hydraulic fitting Loosen hydraulic fitting from Adapter Fitting 1-1/4" and 7/8" wrench Unthread hydraulic fitting from adapter fitting

    • Unthread hose from hydraulic fitting

    • Loosen hydraulic fitting from Adapter Fitting 1-1/4" and 7/8" wrench

    • Unthread hydraulic fitting from adapter fitting

  3. Apply o-ring lubricant to o-ring from kit for hydraulic fitting Replace o-ring around hydraulic fitting with o-ring in kit (smallest o-ring in kit) Loosen adapter fitting from Actuator Housing with1-1/4" and 1-1/16" wrench

    • Apply o-ring lubricant to o-ring from kit for hydraulic fitting

    • Replace o-ring around hydraulic fitting with o-ring in kit (smallest o-ring in kit)

    • Loosen adapter fitting from Actuator Housing with1-1/4" and 1-1/16" wrench

  4. Unthread adapter fitting from actuator housing Apply o-ring lubricant to largest o-ring in kit Replace o-ring on adapter fitting with largest o-ring in kit

    • Unthread adapter fitting from actuator housing

    • Apply o-ring lubricant to largest o-ring in kit

    • Replace o-ring on adapter fitting with largest o-ring in kit

  5. Loosen actuator housing from Valve Body using 1-1/16" and 7/8" wrench Unthread actuator housing from valve body Loosen gland nut from Bleed Down Valve inlet using 5/8" and 3/4" wrench

    • Loosen actuator housing from Valve Body using 1-1/16" and 7/8" wrench

    • Unthread actuator housing from valve body

    • Loosen gland nut from Bleed Down Valve inlet using 5/8" and 3/4" wrench

  6. Unthread gland nut with HP tubing from bleed down valve inlet Clean gland nut of all Blue Goop with isopropyl alcohol Loosen gland nut from outlet fitting using 13/16" and 5/8" wrench

    • Unthread gland nut with HP tubing from bleed down valve inlet

    • Clean gland nut of all Blue Goop with isopropyl alcohol

    • Loosen gland nut from outlet fitting using 13/16" and 5/8" wrench

  7. Unthread gland nut from outlet adapter Clean gland nut of all blue goop with isopropyl alcohol Push Piston out of actuator housing through oil port using included dowel

    • Unthread gland nut from outlet adapter

    • Clean gland nut of all blue goop with isopropyl alcohol

    • Push Piston out of actuator housing through oil port using included dowel

  8. Discard o-ring and backup ring from piston Inspect piston, if damage is visible, replace Apply o-ring lubricant to cover all of o-ring and back-up ring

    • Discard o-ring and backup ring from piston

    • Inspect piston, if damage is visible, replace

    • Apply o-ring lubricant to cover all of o-ring and back-up ring

  9. Slide new back-up o-ring (flat) to groove of piston Make sure concave of back-up ring side is towards o-ring Slide new o-ring (rounded) to groove of piston Insert piston assembly into actuator housing and push with included dowel

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

    • Slide new o-ring (rounded) to groove of piston

    • Insert piston assembly into actuator housing and push with included dowel

  10. Thread adapter fitting to actuator housing Tighten adapter fitting to actuator housing using 1-1/4" and 1-1/16" wrench Loosen 3/8" to 1/4" adapter from bleed down valve outlet adapter using 1" and 13/16" wrench

    • Thread adapter fitting to actuator housing

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

    • Loosen 3/8" to 1/4" adapter from bleed down valve outlet adapter using 1" and 13/16" wrench

  11. Unthread 3/8" to 1/4" adapter from bleed down valve adapter Loosen bleed down valve adapter outlet from bleed down valve using 7/8" and 1" wrench Unthread bleed down valve adapter from bleed down valve

    • Unthread 3/8" to 1/4" adapter from bleed down valve adapter

    • Loosen bleed down valve adapter outlet from bleed down valve using 7/8" and 1" wrench

    • Unthread bleed down valve adapter from bleed down valve

  12. Remove Seat from bleed down valve body Remove Flow Reducer from bleed down valve adapter Clean outlet adapter of all blue goop

    • Remove Seat from bleed down valve body

    • Remove Flow Reducer from bleed down valve adapter

    • Clean outlet adapter of all blue goop

  13. Unthread seal back-up screw from top of bleed down valve body Push components through bleed down valve body with included dowel Clean bleed down valve body with isopropyl alcohol

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

    • Push components through bleed down valve body with included dowel

    • Clean bleed down valve body with isopropyl alcohol

  14. Apply high vacuum grease to Needle Slide back-up screw on to needle to flat end of needle is flush with non threaded part of back-up screw Slide bushing onto point of needle with chamfered end towards back-up screw

    • Apply high vacuum grease to Needle

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

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

  15. Place hoop with tapered end onto non o-ring side of HP Seal Place HP seal assembly onto point of needle with hoop first Apply high vacuum grease to exterior of HP seal, hoop, and bushing

    • Place hoop with tapered end onto non o-ring side of HP Seal

    • Place HP seal assembly onto point of needle with hoop first

    • Apply high vacuum grease to exterior of HP seal, hoop, and bushing

  16. Apply high vacuum grease to internal threads of bleed down valve body Insert high pressure needle assembly into top of bleed down valve body with point first Push seal backup screw inside of valve body until it bottoms out

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

    • Insert high pressure needle assembly into top of bleed down valve body with point first

    • Push seal backup screw inside of valve body until it bottoms out

  17. Take seal backup screw out of body and apply a layer of blue goop to threads Thread in back-up screw into top of bleed down valve body Tighten back-up screw to top of bleed down valve body using a 5/16" ratchet

    • Take seal backup screw out of body and apply a layer of blue goop to threads

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

    • Tighten back-up screw to top of bleed down valve body using a 5/16" ratchet

  18. Place flow reducer into hole beneath seat cavity in the outlet adapter Apply a layer of blue goop to external threads and seat cavity of outlet adapter Place poppet seat into seat cavity of outlet adapter

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

    • Apply a layer of blue goop to external threads and seat cavity of outlet adapter

    • Place poppet seat into seat cavity of outlet adapter

  19. Apply a layer of blue goop to top of poppet seat sitting in outlet adapter Thread outlet adapter into valve body Using a 1" wrench on outlet adapter and a 7/8" wrench on the valve body, tighten securely

    • Apply a layer of blue goop to top of poppet seat sitting in outlet adapter

    • Thread outlet adapter into valve body

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

  20. Apply a layer of blue goop to external threads of valve body Thread valve body into housing Tighten using a 1-1/16" wrench on housing body and a 7/8" wrench on valve body

    • Apply a layer of blue goop to external threads of valve body

    • Thread valve body into housing

    • Tighten using a 1-1/16" wrench on housing body and a 7/8" wrench on valve body

  21. Thread in bleed down valve adapter to bleed down valve outlet Tighten bleed down valve adapter to bleed down valve outlet

    • Thread in bleed down valve adapter to bleed down valve outlet

    • Tighten bleed down valve adapter to bleed down valve outlet

    • Apply blue goop to gland nut

  22. Thread in gland nut with HP tubing into bleed down valve adapter Apply blue goop to gland nut Thread in gland nut to side of bleed down valve body

    • Thread in gland nut with HP tubing into bleed down valve adapter

    • Apply blue goop to gland nut

    • Thread in gland nut to side of bleed down valve body

  23. Tighten gland nut to side of bleed down valve body with.... Thread in hydraulic fitting to adapter fitting Tighten hydraulic fitting to adapter fitting using.....

    • Tighten gland nut to side of bleed down valve body with....

    • Thread in hydraulic fitting to adapter fitting

    • Tighten hydraulic fitting to adapter fitting using.....

  24. Thread hydraulic hose to hydraulic fitting Tighten hydraulic hose to hydraulic fitting using 7/8" and 3/4" wrench Turn pump ON and continue cutting process

    • Thread hydraulic hose to hydraulic fitting

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

    • Turn pump ON and continue cutting process

Author

with 2 other contributors

Adam Dumas

Member since: 5/20/13

36 Guides authored

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