Hypertherm HyPrecision 100D, Instruction Manual

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Intensifier Overstroking in One Direction
This indicates a problem inside the intensifier, specifically the LP poppet or HP check valve area. Verify
that the inlet water is connected to the intensifier. Look for leaking from either end of the HP cylinder.
Replace HP seals if necessary. If the HP cylinder or check valve body is hot, disassemble and look for
cracks. Any component that is cracked must be replaced.
If there are no visible leaks from any weep holes then one of the poppet and seat areas may be bypassing
water. Inspect both of the HP poppets and seats and both LP poppets. Inspect the check valve body-face.
Replace and/or recondition the damaged poppet faces.
7.8 Pump Bleed-Down Valve
The pump bleed-down valve discharges high-pressure water from the pump when the pump is turned
off. It operates as a normally-open safety valve and is controlled by an air-actuated valve. The bleed-
down valve is located inside behind the utility panel at the front of the pump.
Bleed-Down Valve Repair
The Bleed-Down Valve repair kit 12981 contains one each of
the following:
•
Seal Hoop 11323
•
Needle(Stem) 12942
•
Seal, FL 11321
•
Bushing 11324
•
Poppet Seat 11141
Kit installation procedure:
1. Shut down the system.
2. Remove the hydraulic hose from the bleed-down valve and gland nut connection from the water
drain tubing to the bleed-down valve.
3. Remove the gland nut from the collar at the high-pressure port of the bleed-down valve.
4. Disconnect the actuator from the high-pressure valve
assembly. Remove all the hydraulic fittings from
the actuator housing.
5. Remove the adapter from the bleed-down valve
body. Remove and discard the HP seat.
6. Remove all the internal components from the bleed-
down valve body.
7. Push the piston out of the actuator housing body
through the oil port. Discard the o-ring and backup
ring from the piston.
8. Clean all parts before the new parts are installed.
9. Lubricate the new o-ring and backup ring with grease from the supplied packet and install the
rings in the same order as the old O-rings (previous figure). Install the piston assembly carefully
into the actuator body until it is seated securely and no damage has been caused to the o-ring.
10. Secure the hydraulic fitting to the end of the actuator housing.
11. Apply Blue Goop to both sides of the HP seat and to the flow reducer and place them into the
valve body as shown. Tighten the outlet adapter on the end to secure the parts.
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