Hypertherm HyPrecision 100D Instruction Manual page 42

Installing New HP Seals
Parts Needed:
•
Seal replacement tools.
•
Seal kit: 4 HP seals with O-rings, 4 hoops, 1grease packet, bronze seal backup.
1. Place the HP cylinder on the spacer tool, then insert the spacer tube, basket, and
LP poppet
2. Place the locating ring and seal guide on the end of the cylinder. The large ID
end of the seal guide should be up. Coat the inner diameter of the seal guide
with the packet grease.
3. Apply grease from the packet onto each O-ring. Place each O-ring onto the
HP seal while making sure that the O-ring does not twist.
4. Place the seal with O-ring inside the seal guide with the O-ring toward the
cylinder.
5. Push the seal into the bore using the non-stepped end of the seal insertion
tool. Always hold the seal guide firmly against the HP cylinder to prevent
the O-ring from cutting as it enters the bore.
6. Place the silver hoop in the seal guide with the sharp edge toward the
cylinder.
7. Use the non-stepped end of the seal insertion tool and a soft blow hammer
to pound the hoop into place. The hoop is seated properly when the seal
insertion tool bottoms out on the seal guide.
8. Apply a small amount of grease from the packet around the OD of the pilot
on the check valve body.
9. Carefully insert the check valve body into the end of the high-pressure
cylinder until it is seated firmly against the cylinder body. Do not apply
any grease or blue goop to the check valve face or the cylinder bore, these
are designed for dry contact.
10. Flip the cylinder, place it securely on the check valve body, and repeat
steps 3-5. Apply a very light coat of blue goop to the cylinder contact
face.
Use a clean rag to wipe the interior of the LP basket so that
there is no grease to make the LP poppet stick.
IMPORTANT
The bronze backup seal can be reused only once. Install
either a new backup or reuse (flip) the old one. It may be
necessary to pull the seal housing out slightly to access
and remove the backup. (See the Hydraulic Seal Housing
section.)
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