Hypertherm - Cut with Confidence

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Image 1/2: Turn OFF all water pressure to the on/off valve. Image 2/2: Turn the on/off valve ON to raise  [http://www.accustream.com/waterjet-parts/flow/flow-on-off-valve/insta-1-valve-parts/11140.html|poppet stem] from the [http://www.accustream.com/all-products/11141.html|poppet seat].
  • 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 water pressure to the on/off valve.

  • Turn the on/off valve ON to raise poppet stem from the poppet seat.

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Image 1/2: Unthread the [http://www.accustream.com/all-products/11358-4.html|nozzle tube] from the valve body using 3/4" and 7/8" wrench. Image 2/2: Unthread the [http://www.accustream.com/all-products/11358-4.html|nozzle tube] from the valve body using 3/4" and 7/8" wrench.
  • The valve kit components can be replaced with the valve body in the mounting collar.

  • Unthread the nozzle tube from the valve body using 3/4" and 7/8" wrench.

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Image 1/3: Disconnect the air line from the actuator. Image 2/3: Unthread the actuator from the valve body using 1-1/8" wrench. Image 3/3: Unthread the actuator from the valve body using 1-1/8" wrench.
  • Turn the air to the cctuator OFF at the controls.

  • Disconnect the air line from the actuator.

  • Unthread the actuator from the valve body using 1-1/8" wrench.

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Image 1/3: Thoroughly clean the interior/exterior of the valve body with isopropyl alcohol or a similar cleaning agent before replacing the components. Image 2/3: Visually inspect the top and bottom of the bore for cracks/blemishes.  If excessive wear or cracks are visible, replace the [http://www.accustream.com/all-products/11144.html|valve body]. Image 3/3: Visually inspect the top and bottom of the bore for cracks/blemishes.  If excessive wear or cracks are visible, replace the [http://www.accustream.com/all-products/11144.html|valve body].
  • Remove the old valve components from the valve body with the included dowel.

  • Thoroughly clean the interior/exterior of the valve body with isopropyl alcohol or a similar cleaning agent before replacing the components.

  • Visually inspect the top and bottom of the bore for cracks/blemishes. If excessive wear or cracks are visible, replace the valve body.

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Image 1/3: Apply a high-pressure lubricant or similar ([http://www.accustream.com/all-products/11136.html|11136]) to the  outside diameter of the high-pressure valve seal. Image 2/3: Slide the [http://www.accustream.com/all-products/11143.html|back-up ring] on to the poppet stem behind the high-pressure valve seal. Image 3/3: Slide the [http://www.accustream.com/all-products/11143.html|back-up ring] on to the poppet stem behind the high-pressure valve seal.
  • With the O-ring towards the point of the poppet stem, slide the high-pressure valve seal on to the poppet stem.

  • Apply a high-pressure lubricant or similar (11136) to the outside diameter of the high-pressure valve seal.

  • Slide the back-up ring on to the poppet stem behind the high-pressure valve seal.

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Image 1/3: Use the dowel to push the poppet stem down until the back-up ring is flush with the top of the bore. Image 2/3: Apply  [http://www.accustream.com/all-products/11111.html|Blue Goop] to the top threads of the valve body. Image 3/3: Apply  [http://www.accustream.com/all-products/11111.html|Blue Goop] to the top threads of the valve body.
  • Put the poppet stem, with the point down, at the top of the valve body.

  • Use the dowel to push the poppet stem down until the back-up ring is flush with the top of the bore.

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

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Image 1/3: Thread the valve screw into the valve body until it bottoms out. Image 2/3: With the dowel, push the poppet stem point flush with the bottom of the bore. Image 3/3: With the dowel, push the poppet stem point flush with the bottom of the bore.
  • Apply Blue Goop to the valve screw threads.

  • Thread the valve screw into the valve body until it bottoms out.

  • With the dowel, push the poppet stem point flush with the bottom of the bore.

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Image 1/3: Put the poppet seat at bottom of the valve body. Image 2/3: Put the  [http://www.accustream.com/all-products/11145.html|O-ring] behind the poppet seat so it is held in place. Image 3/3: Put the  [http://www.accustream.com/all-products/11145.html|O-ring] behind the poppet seat so it is held in place.
  • Apply Blue Goop to all surfaces of the poppet seat.

  • Put the poppet seat at bottom of the valve body.

  • Put the O-ring behind the poppet seat so it is held in place.

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Image 1/3: Reconnect the air line to the top of the actuator. Image 2/3: Turn the air to the actuator ON to relieve the pressure from the poppet. Image 3/3: Turn the air to the actuator ON to relieve the pressure from the poppet.
  • Thread (hand tighten) the actuator on top of the valve body.

  • Reconnect the air line to the top of the actuator.

  • Turn the air to the actuator ON to relieve the pressure from the poppet.

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Image 1/3: Reapply Blue Goop to the threads of the nozzle tube. Image 2/3: Thread the nozzle tube into the bottom of the valve body. Image 3/3: Thread the nozzle tube into the bottom of the valve body.
  • Thoroughly clean the nozzle tube of all Blue Goop.

  • Reapply Blue Goop to the threads of the nozzle tube.

  • Thread the nozzle tube into the bottom of the valve body.

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Image 1/3: Turn the air to the actuator OFF to set the poppet stem into the poppet seat. Image 2/3: Apply water pressure to the valve assembly to verify that there are no leaks. Image 3/3: Apply water pressure to the valve assembly to verify that there are no leaks.
  • Tighten the nozzle tube to the valve bodye using 3/4" and 7/8" wrench.

  • Turn the air to the actuator OFF to set the poppet stem into the poppet seat.

  • Apply water pressure to the valve assembly to verify that there are no leaks.

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Image 1/2: Re-install the cutting head and continue the cutting process. Image 2/2: Re-install the cutting head and continue the cutting process.
  • Quickly cycle the valve on and off a few times to purge the system of all contaminants before installing the cutting head.

  • Re-install the cutting head and continue the cutting process.

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Finish Line

One other person completed this guide.

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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