Hypertherm HyPrecision 100D Instruction Manual page 41

Removing Old HP Seals
1. Remove the high-pressure tubing and inlet water quick-disconnects from
the appropriate end of the intensifier.
2. Remove the four 1 in. nuts from the studs by using a cross pattern to
gradually unload the high-pressure end cap from the high-pressure
cylinder.
3. Remove the HP end cap and the check valve body from the HP cylinder.
4. Remove the HP cylinder (1) from the plunger (2) and the LP poppet (7)
from the static end of the HP cylinder.
The dynamic end of the cylinder is the end towards the intensifier center and the
static cylinder end is the outboard side and contains the LP poppet.
5. Place the stepped (static) end of the cylinder on the seal-tool locating ring. Use a rubber mallet at
the small end of the push tool to drive the bottom seal and hoop out of the HP cylinder. Flip the
cylinder over and repeat the process. The seals (4) with O-rings (6), hoops (5), spacer tube (3),
and low-pressure poppet basket (8) should now be free of the HP cylinder.
6. Remove the bronze seal backup (9) from the seal housing in the hydraulic end cap. It may require
partially removing the seal housing. See the Hydraulic Seal Housing subsection of the High-
Pressure Water section for housing removal instructions.
7. Clean and inspect all disassembled parts. If the bronze seal backup (9) is to be reused, verify that
the weep hole and ID groove are clear.
*See the High-Pressure Cylinder subsection for reconditioning of the HP cylinder and check valves.
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