Hypertherm - Cut with Confidence

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  1. Always make sure that 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 that 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 a 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 gland nut on the high-pressure tubing at the high-pressure inlet port of the bleed-down valve using a 13/16" and 5/8" wrench.

    • Unthread the gland nut from the outlet fitting at the high-pressure inlet port of the bleed-down valve.

    • Clean the gland nut of all Blue Goop with isopropyl alcohol or a similar cleaning agent.

    • Loosen the gland nut from the outlet fitting (connected to the valve body) using a 13/16" and 5/8" wrench.

    • Unthread the gland nut from the outlet fitting (connected to the valve body).

    • Clean the gland nut of all the Blue Goop.

    • Loosen the hydraulic fitting from the adapter fitting using a 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 around the hydraulic fitting with the O-ring from the kit (the smallest O-ring from the kit).

    • Loosen the adapter fitting from the actuator housing using a 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 a 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 the back-up ring from the piston.

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

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

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

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

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

    • Put the piston assembly into the actuator housing the the groove side first and push the piston with the included dowel until the piston bottoms out.

    • Loosen the 3/8" to 1/4" adapter from the outlet fitting using a 7/8" and 13/16" wrench.

    • Unthread the 3/8" to 1/4" adapter from the outlet fitting.

    • Loosen the outlet fitting from the bleed down valve body using a 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.

    • Remove the flow reducer from the outlet adapter.

    • Clean the outlet adapter of all the Blue Goop.

    • Clean the high-pressure seat of all the Blue Goop.

    • With the bleed down valve tool push through the bleed-down valve body to remove all components.

      • The oil seal can also be removed by the bleed down valve tool.

    • Thoroughly clean the valve body before replacing the components.

    • Visually inspect the top/bottom of the valve body, if excessive wear or cracks are visible, replace the valve body.

    • Put the high-pressure seal on to the bleed-down valve tool with the O-ring towards the bleed down valve tool.

    • Slide the hoop, with the sharp edge first, on to the bleed-down valve tool behind the high-pressure seal.

    • Slide the bushing on the bleed-down valve tool with the chamfer side away from the hoop.

    • Apply a high-pressure lubricant to the high-pressure seal, hoop, and bushing.

      • The O-ring on the high-pressure seal can pinch or strip when installing into the valve body.

    • Put the bleed-down valve tool with the parts into the bottom of the valve body until the tool reaches the bottom of the valve.

      • Be aware that the inner diameter of the valve body has a small step, it can pinch or strip the O-ring from the high-pressure seal during installation.

    • Apply a high-pressure lubricant to the stem.

    • Replace the oil seal, place on the top of the valve body.

      • Put the concave (rubber) side down towards the valve body.

    • Put the stem through the high-pressure seal until it is flush with the oil seal.

    • Apply Blue Goop to all surfaces of the high-pressure seat.

    • Put the high-pressure seat at the bottom of the bleed-down valve body with the pointed end out.

    • Apply Blue Goop to the outlet adapter threads.

    • Put the flow reducer in the outlet adapter.

    • Thread the outlet adapter into the valve body.

    • Tighten the outlet adapter to the valve body using a 7/8" and 13/16" wrench.

    • Thread the 3/8" to 1/4" adapter to the outlet adapter.

    • Tighten the 3/8" to 1/4" adapter to the outlet adapter using a 7/8" and 13/16" wrench.

    • Apply Blue Goop to the top threads of the valve body.

    • With the piston assembly installed, thread the actuator housing onto the valve body.

    • Tighten the actuator housing to the valve body using 1-1/16" and 7/8" 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 adapter into the adapter fitting.

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

    • Apply Blue Goop to the threads of the gland nut.

    • Thread the gland nut into the outlet fitting (connected to the valve body).

    • Tighten the gland nut to the outlet fitting (connected to the valve body) using 13/16" and 5/8" wrench.

    • Apply Blue Goop to the gland nut threads.

    • Thread the gland nut into the outlet fitting (connected to the collar).

    • Tighten the gland nut into the outlet fitting (connected to the collar) using a 13/16" and 5/8" wrench.

    • Thread the hydraulic hose on to the hydraulic fitting.

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

    • Turn the pump ON and continue the cutting process.

Finish Line

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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