How to Repair a Flow Style High-Cycle On/Off Valve (Insta 2) Using Kit #13687

Written By: Adam Dumas (and 2 other contributors)
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Difficulty

Moderate

Steps

11

Time Required

00:20:00 - 00:30:00

Sections

1

Flags

0

Introduction

Hypertherm is in no way affiliated with the above mentioned manufacturer.

  1. Always make sure all high-pressure water has been removed from the valve by the 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

    • Always make sure all high-pressure water has been removed from the valve by the 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 the poppet stem from the high-pressure seat.

  2. The valve kit components can be replaced with the valve body in the mounting collar Unthread the nozzle tube from the valve body using a 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 a 3/4" and 7/8" wrench.

  3. Turn the air to the actuator OFF at the controls Disconnect the air tube from the actuator. Unthread the actuator from the valve body using 1-1/8" wrench.

    • Turn the air to the actuator OFF at the controls

    • Disconnect the air tube from the actuator.

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

  4. 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.

    • 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.

  5. Put the bushing stem onto the poppet stem. With the O-ring down, slide the high-pressure valve seal onto the poppet stem behind the bushing stem. Apply a high-pressure lubricant or similar (11136) to the outside diameter of the high-pressure valve seal.

    • Put the bushing stem onto the poppet stem.

    • With the O-ring down, slide the high-pressure valve seal onto the poppet stem behind the bushing stem.

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

  6. Put the back-up ring with the concave side towards the high-pressure seal on the poppet stem behind the high-pressure seal. 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.

    • Put the back-up ring with the concave side towards the high-pressure seal on the poppet stem behind the high-pressure seal.

    • 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.

  7. Apply Blue Goop to the top of the valve body threads. Thread (hand tighten) the actuator to the top of the valve body. Reconnect the air line to the top of the actuator.

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

    • Thread (hand tighten) the actuator to the top of the valve body.

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

  8. Apply Blue Goop to all surfaces of the high-pressure seat. Put the high-pressure seat at the bottom of the valve body. Put the O-ring behind the high-pressure seat so it is held in place.

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

    • Put the high-pressure seat at the bottom of the valve body.

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

  9. Turn the air to the actuator ON to relieve the pressure from the poppet stem. Thoroughly clean the nozzle tube of all the Blue Goop. Reapply Blue Goop to the threads of the nozzle tube.

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

    • Thoroughly clean the nozzle tube of all the Blue Goop.

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

  10. Thread the nozzle tube into the bottom of the valve body. Tighten the nozzle tube to the valve body using 3/4" and 7/8" wrench. Turn the air to the actuator OFF to set the poppet stem into the high-pressure seat.

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

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

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

  11. Apply water pressure to the valve assembly to verify there are no leaks. Quickly cycle the valve on and off a few times to purge the system of all contaminants before installing the cutting head. Reinstall the cutting head and continue the cutting process.

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

    • Quickly cycle the valve on and off a few times to purge the system of all contaminants before installing the cutting head.

    • Reinstall the cutting head and continue the cutting process.

Finish Line

Author

with 2 other contributors

Adam Dumas

Member since: 05/20/2013

36 Guides authored

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