What NOT to Do When Rebuilding a Hytrol Valve

The “Hytrol” is Cla-Val’s original diaphragm-actuated control valve and is used in 75% of control valve applications, including pressure reducing, pressure relief, altitude and flow control valves. Rebuilding your Hytrol valve extends its lifespan and prevents system failures, but the process can be tricky—especially if you’re not following best practices. In this article, we’re highlighting six common mistakes to avoid when rebuilding your Hytrol valve. Skip these mistakes, and you’ll be well on your way to a successful Hytrol rebuild!

1. Don’t Take the Valve Apart Until You’ve Isolated It

We’ve all been there—you think you’ve properly isolated the valve, but the moment you loosen or remove a fitting, you get a cold blast of water. The last thing you need is to start your day wet and cold. So unless you want to create a new water feature in the vault, always double-check that the valve is fully isolated from the system before you start dismantling it!

2. Don’t Take the Valve Apart Unless You Know the Proper Orientation of Each Component

Tearing a valve apart is easy! Putting it back together is the tricky part. Pay careful attention to how each part is oriented. It’s easy to put a component back upside down or in the wrong position, which could cause the valve to malfunction. To avoid this, always reference this parts diagram. If you’re new to working on Hytrol valves, make sure you have a clear understanding of the parts layout before you begin.

3. Don’t Reuse the Rubber

Rubber components should always be replaced during a rebuild. Even if the rubber looks fine, its properties degrade over time. Rebuilding the valve without replacing the rubber is risky, as it’s much more likely to fail prematurely. Some operators have tried to flip the rubber and use the "fresh" side… but when it comes to a valve diaphragm or disc there’s no such thing as a “fresh side.” Once the rubber is used/worn, it’s time for a replacement.

4. Don’t Reuse a Bad Part

If a part shows any sign of wear—gouging, erosion, or damage—replace it immediately. Using compromised parts can lead to costly repairs down the line. We stock parts for valves up to 12 inches, so there’s no reason to take a chance with damaged components. Larger parts may take a couple of days to ship, but even then, it’s worth the wait for the right part.

5. Don’t Use Generic Parts on a Cla-Val

Cla-Val valves are precision-engineered and machined, and using generic or mismatched parts can compromise their performance. Aftermarket parts aren’t made to the same tolerances as Cla-Val parts so they can stick or fit loosely, resulting in premature wear or failure. We’ve seen cases where aftermarket parts caused significant damage to other parts in the valve and to the water systems they supply. Stick with Cla-Val parts for your Cla-Val valves to maintain proper functionality and extend the life of your valve and system.

6. Don’t Leave Foreign Objects in the Valve

It may sound obvious, but don’t leave stuff in valves! We’ve found rags, gloves, and even wrenches inside valves we’ve serviced. (Hmm… I wonder why it’s not operating properly!?) Especially when working on large valves, it’s easy to set something down and forget about it. Before closing up the valve, always double-check the interior to ensure that no foreign objects have been left behind in the valve body or cover chamber.

Conclusion:

Unless you enjoy rebuilding your valves more frequently than the recommended every 3-5 years, you’ll want to avoid these common mistakes! At the end of the day, we’re here to support you with parts, advice, and expertise to make valve maintenance as easy as possible. If you ever need guidance or parts, don’t hesitate to reach out to us!

Get service or troubleshooting support >