High Pressure Motor Valves - Home | Kimray Mobile - Kimray, Inc.

Repair Manual 

High Pressure Motor Valves

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL 

INDEX 

Introduction .................................................................................................... 1 

Elastomers ..................................................................................................... 2 

Materials ........................................................................................................ 3 

Pressure Open to Pressure Close Conversion .............................................. 5 

HPMV Disassembly ....................................................................................... 9 

HMPV Inspection of Parts ............................................................................ 17 

HPMV Assembly .......................................................................................... 19 

HPMV Testing .............................................................................................. 25 

Piston Balanced Disassembly ..................................................................... 27 

Piston Balanced Inspection of Parts ............................................................ 35 

Piston Balanced Assembly .......................................................................... 37 

NOTE: We reserve the right to modify or change, without prior 

notice, any statement or information contained herein. If exact 

dimensions or specifications are required by the customer 

certified prints will be furnished for a minimum charge upon 

request to KIMRAY, Inc. 

® Copyright 2006, KIMRAY, Inc. 

www.kimray.com

HIGH PRESSURE MOTOR VALVE REPAIR MANUAL 

INTRODUCTION 

SCOPE 

This instruction manual contains repair information for the standard 1" and 2" Kimray High Pressure Motor 

Valve and the 2” through 6” Piston Balanced High Pressure Motor Valve. 

DESCRIPTION 

The High Pressure Motor Valves are all actuated with a pneumatic actuator which features an open yoke and 

travel indicator. The actuators are reversible between pressure opening and pressure closing configurations. 

The standard High Pressure Motor Valve employs a ball and cone seat configuration. The Piston Balanced 

High Pressure Motor Valve shuts off with a resilient seat. 

OPERATION 

The Kimray High Pressure Motor Valves require no more than 30 psig to operate. The pneumatic pressure 

drives a diaphragm against a return spring. When pneumatic pressure is relieved, the valve shuts. 

MAINTENANCE 

Maintenance should be performed on a regular basis. An initial inspection interval of 12 months is recommended. 

Depending on the service conditions and the condition of the valve, the inspection interval may be 

decreased or increased. The valve can be repaired without being removed from the piping. 

WARNING 

Before performing any service be sure that the valve is fully isolated and that all pressure upstream and 

down has been relieved. 

• Use bypass valves or fully shut off the process 

• Be sure that any operating or instrument gas lines have been disconnected. 

• Never assume that a check valve is fully blocking the downstream line. 

• Never tighten any fitting or the main connections to the regulator while there is pressure on the line. 

To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAY 

PARTS when doing repairs. Remember, parts made to less than Kimray specifications don’t save you 

money!!! 

ENG-002.3 REV. 3 Issued 1-17-2007 

www.kimray.com Page 1


ELASTOMERS 

TEMPERATURE: 

-25° to +500° F 

-30° to +260° C 

APPLICATION: 

Crude Oil & Gas Production (High heat), Steam Flood 

Production Chemicals (corrosion inhibitors) Amine 

Sweetener Systems, Gasoline, Diesel, Fuel Oil Systems 

FLUID / GAS: 

Crude Oil & Gas Production, H2S, Steam, Petroleum 

fluids, Sea Water 

TEMPERATURE: 

-15° to +300° F 

-26° to +149° C 

APPLICATION: 

Crude Oil & Gas Production w/ H2S C02 

FLUID / GAS: 

Crude Oil & Gas H2S, C02, Sea Water 

TEMPERATURE: 

Buna-N: 

-40° to +220° F 

-40° to +105° C 

Low-Temp: 

-85° to +120° F 

-65° to +49° C 

APPLICATION: 

Crude Oil & Gas Production Glycol Dehydrators, 

Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal, 

Methanol Injection Pumps, Water pump seals, hydraulic 

pump seals 

FLUID / GAS: 

Crude Oil & Gas, Good to Poor in Sour Production (See 

HSN), Water, Glycols, Hydraulic Oils, Resistance to crude 

oil in the presence of hydrogen sulfide and amines, Diesel 

fuel, fuel oils 

DO NOT USE WITH: 

Aromatic hydrocarbons, chlorinated hydrocarbons, 

phosphate esters (hydraulic fluids) 

TEMPERATURE: 

-350° to +500° F 

AFLAS ® is a trade mark of Asahi Glass Co 

HSN (Highly Saturated Nitrile) 

NITRILE 

GYLON 

APPLICATION: 

High heat, high chemical resistance, highly resistance 

to gas permeation 

TEMPERATURE: 

-10° to +350° F 

-23° to +177° C 

APPLICATION: 

Crude Oil & Gas Production, Glycol Dehydrators, 

Gasoline, Jet Fuel & Diesel Fuel Pumping, Water Disposal, 

Methanol Injection Pumps. (Also Vacuum Service) (Gas 

permeability is very low) 

FLUID / GAS: 

Crude Oil & Gas, Sour Gas (C02), Propane, Gasoline, 

Diesel, Fuel Oil Systems 


Hot Water, Not preferred for wet H2S, Methyl Alcohol, 

Amines, Sodium hydroxide solutions 

TEMPERATURE: 

-65° to +300° F 

-54° to +148° C 

APPLICATION: 

Steam Flood 

FLUID / GAS: 

Steam, Water, Alcohol 


Crude Oil & Gas, Diester Lubricants (Lube Oils) 

TEMPERATURE: 

-40° to +220° F 

-40° to +104° C 

APPLICATION: 

High abrasion resistance Seats, Diaphragms 

FLUID / GAS: 

Crude Oil gas and Water, Sour Gas (C02), propane, 

butane, fuel, mineral oil and grease 

TEMPERATURE: 

±0° to +300° F 

-17° to +149° C 

VITON ® is a trade mark of Dupont 

ETHYLENE PROPYLENE 

POLYURETHANE 

POLYACRYLATE 

APPLICATION: 

Production Heaters, Thermostats 

FLUID / GAS: 

Crude Oil & Gas at High Temperature 


Alcohol, Glycols, Hydrocarbons 

Page 2 

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MATERIALS 

Standard materials in the standard Kimray High Pressure Motor Valve include: 

Exterior Parts: 

Bonnet 

Body 

Interior Parts: 

Stem 

Cage 

Stuffing Box 

Seat 

Plug 

Elastomers: 

Packing 

O-Rings 

Diaphragm 

Ductile Iron ASTM - A395 

Cast Steel ASTM - A216 WCB 

303 Stainless Steel 

Free Machining Steel AISI 12L14 


Tool Steel AISI D2 

Carbide/303 Stainless 

Nitrile/Teflon 

Nitrile 

Nitrile 

Standard materials in the Kimray Piston Balanced High Pressure Motor Valve include 

Exterior Parts: 

Bonnet: 

Body 

Interior Parts: 

Upper Housing 

Stem 

Cage 

Stuffing Box 

Seat 

Piston 

Elastomers: 

Packing 

O-Rings 

Diaphragm 

Ductile Iron ASTM - A395 

Cast Steel ASTM - A216 WCB 

Steel AISI C1018 






Nitrile/Teflon 

Nitrile 

Nitrile 

To get the long service you have come to expect from Kimray products, always use GENUINE KIMRAY 

PARTS when doing repairs. Remember, parts made to less than Kimray specifications don’t save you 

money!!! 



NOTES 

Page 4 

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PRESSURE OPEN TO PRESSURE CLOSE CONVERSION 

STEP 1 

BLOCK DISSASEMBLY 

Start from disassembling the Travel 

Indicator Block (Fig. 1.1) 

STEP 2 

BREATHER PLUG 

Remove the breather plug from the 

Bonnet (Fig. 2.1) 

Figure 1.1 

STEP 3 

ADJUSTING SCREW 

Remove the Adjusting Screw from top of 


Figure 2.1 

STEP 4 

PIVOT 

Remove Pivot from Adjusting Screw 

(Fig. 4.1) 

Figure 3.1 

STEP 5 

BONNET 

Remove the Bonnet by loosing the bolts 

(Fig. 5.1 and 5.2) 

Figure 4.1 

Figure 5.1 Figure 5.2 




STEP 6 

SPRING 

Remove the Spring from the Diaphragm 

Plate (Fig. 6.1) 

STEP 7 

DIAPHRAGM PLATE 

Use an adjustable wrench to hold the 

Upper Stem (Fig. 7.1) while loosening the 

Diaphragm Plate (Fig. 7.2) 

Figure 6.1 

Remove the Diaphragm Plate from the 

Yoke (Fig. 7.3) 


STEP 8 

RETRIEVING O-RING 

NOTE: THIS STEP SHOULD BE FOL- 

LOWED IF YOU DO NOT HAVE AN 

EXTRA O-RING. 

Remove the bolts from the Yoke (Fig. 8.1) 

Flip the Yoke upside down and loosen the 

Lower Adjusting Screw (Fig. 8.2) 

Figure 7.3 


Use a pick remove the O-Ring from the 

Adjusting Screw (Fig. 8.3) 

After the O-Ring has been removed, tighten 

Adjusting Screw back in Yoke and then 

attach Yoke back to Body. 

Figure 8.3 

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STEP 9 

DIAPHRAGM ASSEMBLY 

Insert the Pivot in the bottom of the Yoke 

(Fig. 9.1) 

Place the Spring Plate on top of the Pivot 

(Fig. 9.2) 

Insert the Spring on top of the Spring 

Plate with the Spring plate on top (Fig. 

9.3) 


Insert the Diaphragm Plate on top of the 

Spring (Fig. 9.4) 


Upper Stem (Fig. 9.5) while tightening the 



Insert bolts in Bonnet (Fig. 9.7) and tighten 

them with an impact gun (Fig. 9.8) 


Insert O-Ring on the Upper Adjusting 

Screw (Fig. 9.9) and tighten it on top of 







STEP 10 

BREATHER PLUG 

Insert Breather plug on Yoke (Fig. 10.1) 

STEP 11 

COUPLING BLOCK 

When you assemble the Coupling Block, 

make sure the bevels are in the same 

side of the block as show in (Fig.11.1) 

Figure 10.1 

Place the threaded half Block on back 

side (Fig 11.2) 


Tighten the bolts in the Coupling Block 

with a socket (Fig. 11.3) 

Make sure the Travel Indicator tag shows 

the correct operation of the valve. 

(Fig. 11.4) In this case we are converting 

from Pressure Opening to Pressure Close 


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HPMV DISASSEMBLY 

KIMRAY TOOLS 

Seat Pullers 

Figure A shows the Kimray’s Seat & Cage 

Removal Tool. The handles flange the 

disc to the body while pulling the seat or 

cage. 

Figure B shows a Kimray’s Seat Removal 

Tools able to remove the seat from body 

when the cage has been removed. 

KIMRAY SEAT & CAGE 

REMOVAL TOOL 

PART # 

Figure A 

LINE SIZE 

3032 1" 

3033 2" 

KIMRAY SEAT 

REMOVAL TOOL 

PART # 

Figure B 

LINE SIZE 

615 1" 

614 2" 

STEP 1 

AJUSTING SCREW 

Use a socket to remove the adjusting 

screw on top of the Bonnet (Figure 1.1 

and 1.2) 

STEP 2 

BONNET 

Remove the bolts in the interface between 

the Bonnet and the Yoke (Fig. 2.1) 


Remove Breather Plug From Bonnet 

(Fig. 2.2) 


Remove Bonnet from Yoke (Fig. 2.3) 

Figure 2.3 



HPMV DISSASEMBLY 

STEP 3 

SPRING 

Remove Pivot from top of the spring plate 

(Figure 3.1) 

Remove Spring Plate from top of the 

Spring (Figure 3.2) 

Remove the spring from top Spring Plate 

(Fig. 3.3) 


STEP 4 


Figure 3.3 

BOLTED DIAPHRAGM NUT: 

Spin the Diaphragm plate in a counter 

clock wise direction loosing it from the 

Upper Stem while holding the Upper Stem 

with a small crescent wrench (Fig. 4.1). 

If the HPMV has screws holding the 

Diaphragm, use a screw driver to remove 

them (Fig. 4.2) 


Remove the Diaphragm Nut from the 


Remove the Diaphragm from the 


THREADED DIAPHRAGM NUT: 

Use a pair of piers to remove the 

Diaphragm Nut (Fig. 4.5) 





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STEP 5 

TRAVEL INDICATOR 

Remove the bolts from the travel Indicator 

Block (Fig. 5.1) 

Remove the Block from stem (Fig. 5.2) 

STEP 6 

YOKE ASSEMBLY 

Use a wrench to remove the bolts from 

the Yoke base (Fig. 6.1) 


Slide out the Yoke from the Body 

(Fig. 6.2) 


Flip the Yoke upside down, then take a 

socket and remove the Lower Adjusting 

Screw with an impact gun 

(Fig. 6.3 and 6.4) 


Slide out the Upper Stem from the Lower 


Remove the outside O-Ring from the 



Remove O-Ring from the inside of the 


Use a pair of snap ring pliers to remove 

the Snap Ring (Fig. 6.8) 





Remove the Retainer washer (Fig. 6.9) 

Remove the Wiper from the Lower 


STEP 7 

STUFFING BOX ASSEMBLY 

Use an adjustable wrench to remove the 

stuffing Box from the Body (Fig. 7.1) 


Remove the Stuffing Box from the Body 

(Fig. 7.2) 


Clamp the two flat sides of the Stuffing 

Box in vise and loosen seat with an 

adjustable wrench. (Fig. 7.3) 

Leave the Seat attached to cage. Insert a 

screw driver through cage and unscrew 

(Figure 7.4). 

Note: Leaving the seat attached prevents 

the cage from egg shaping. 


Pull Stem and Cage out of Stuffing Box 

(Fig. 7.5), if it doesn’t come out then flip 

the Stuffing Box over and tap the Stem 

with a hammer and a small punch (Fig. 

7.6) 


Remove Cage and Stem from the Stuffing 

Box (Fig. 7.7) 

Remove the Spring (Fig. 7.8) 


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Remove the Cage from the Ball and Stem 

(Fig. 7.9) 

Remove O-Ring from the Seat (Fig 7.10) 

Remove O-Ring from Stuffing Box (Fig. 

7.11) 

Remove Follower from the Stuffing Box 

(Fig. 7.12) 


Remove the Packing Rings from the 

Stuffing Box (Fig. 7.13) 


Remove the Packing Sleeve from the 





Remove the Retainer washer from the 


Remove the Wiper from the Stuffing Box 

(Fig. 7.17) 


Figure 7.17 




SPECIAL CASES 

SEAT PULLERS 

Some times the Seat does not come out 

with Stuffing Box and Cage. We have a 

couple of options if this happens. 

First Option: 

If the Seat is the only part that stays stuck 

in Body: 

1. Use the wire seat pullers and insert 

them in seat (Fig. 8.1). 

2. Slide a wrench or small rod 

between the wire Seat Pullers 

3. Tap up pulling the seat out 

(Fig. 8.2) 

Figure 8.1 

Second Option: 

If the Stuffing Box comes out by it self 

leaving seat, Ball & Stem and Cage stuck 

in Body. 

1. Thread Seat & Cage Removal Tool 

on to Cage (Fig. 8.3) 

2. Tighten flange down against Body 

3. Pull Case and Seat out of Body 

(Figure 8.4) 

Figure 8.2 


The other end of the tool is used in case 

just the Seat stays in Body.(Fig. 8.5) 

1. Thread Seat & Cage Removal Tool on 

seat 

2. Tighten flange against Body 

3. Pull the seat out by turning the handle 

in a clock wise direction 

Figure 8.5 

Page 14 

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SHOP MADE SEAT REMOVAL TOOL 

This seat removal tool can be made with the following 

parts: 

QTY PART DESCRIPTION 

1 2889 Cage 

1 2837 Cage 

2 Stops Disc 1 3/4"Ø x 3/4" 

1 Rod 13/8"Ø x 22" 

1 Handle 11 3/4 o.d. x 3/8 i.d. x 5 1/2" lg. 

22" 

3" 2 1/2" 

3/4" 

5 1/2" 

1 3/4" 

1 3/4" 

PART 2889 PART 2837 

Figure 9.1 

If Seat is stuck in Body (Fig. 9.2), use the 

appropriate cage size and thread on seat. 

(Fig. 9.3). 

Figure 9.2 

Slide Handle forcefully upwards until you 

hit the upper stop (Fig. 9.4). The Handle 

impact will break loose the seat. 




NOTES 

Page 16 

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HPMV INSPECTION of PARTS 

MOST COMMONLY REPLACED PARTS 

• Seat 

• Stem & Ball 

• Diaphragm 

• O-Rings 

• Packing 

OCCASIONALLY CHANGED PARTS 

• Body 

• Spring 

BALL & STEM 

Check for scratches 

Replace: 

• If there are scratches present 

(Fig. 1.1) 

SEAT 

Figure 1.1 

Replace: 

• If the seat has indication of leakage 

(Fig 2.1) 

BODY 

Figure 2.1 

Replace: 

• If grooves are present on the seating 

surface (Fig.3.1) 

Figure 3.1 



NOTES 

Page 18 

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HPMV ASSEMBLY 

STEP 1 


CASE 1 

BOLTED DIAPHRAGM NUT: 

Tighten Diaphragm Base Plate in Vice 

(Fig. 1.1) 

Insert Diaphragm on the Diaphragm Plate 

aligning holes with both parts (Fig. 1.2) 


Insert Diaphragm Plate in to Base Plate 

making sure holes are aligned (Fig. 1.3) 

Use gasket sealant material to dip each 

screw in before putting in hole. Tighten 

screws in a criss-cross pattern and then 

retighten very tight (Fig. 1.4) 

CASE 2 

THREADED DIAPHRAGM NUT: 


Tighten Diaphragm Plate in vice and 

insert Diaphragm on the Diaphragm Plate 

(Fig. 1.5) 

Grease the Diaphragm inside edge (Fig. 

1.6) 


Insert the Diaphragm Nut and use a pair 

of pliers to tighten (Fig. 1.7) 

Note: Make sure the Diaphragm does not 

wrinkle. 

STEP 2 


Insert Wiper in the Stuffing Box (Fig. 2.1) 

Figure 1.7 

Insert the retainer with the sharp edge on 

top (Fig. 2.2) 




HPMV ASSEMBLY 

Use a pair of snap ring pliers to insert the 

Snap Ring (Figure 2.3) 

Insert the packing rings on the Packing 

Sleeve (Fig. 2.4) 

Grease the Packing before inserting it in 

the stuffing Box, with the large blue end of 

sleeve down (Fig. 2.5) 

Grease the Stuffing Box (Fig. 2.6) 



Insert the Packing in the Stuffing Box 

(Fig. 2.7) 

Use a socket to push the Packing down 

(Fig. 2.8) 

Insert Follower in the Stuffing Box (Fig. 

2.9) 

Fill the Stuffing Box with grease 

(Fig. 2.10) 


Insert O-Ring on Stuffing Box (Fig. 2.11) 

Insert Spring in the Stuffing Box 

(Fig. 2.12) 



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HPMV ASSEMBLY 

Insert O-Ring on Seat (Fig. 2.13) 

Introduce the Stem in Cage (Fig. 2.14) 


Thread the Seat in Cage (Fig. 2.15) 

Place the flat edges of stuffing box in vice 

(Fig. 2.16) 


Insert Seat, Cage and Stem in the stuffing 

Box and tighten with a wrench 

(Fig. 2.17 and 2.18) 


Tap the Stem until Ball seats (Fig. 2.19) 

Use a brush to grease O-Rings (Fig. 2.20) 

STEP 3 

BODY 

Flip the Body upside down and tighten 

Body on Stuffing Box Assembly 

(Fig. 3.1 and 3.2) 





HPMV ASSEMBLY 

BODY TESTING: 

Apply air pressure on the upstream side 

of the valve (Fig. 3.3) 

Test for leakage in the downstream side 

STEP 4 

LOWER ADJUSTING SCREW 

Insert O-Ring in the Lower Adjusting 

Screw (Fig. 4.1) 

Figure 3.3 

Flip the Lower Adjusting Screw over and 

insert Wiper (Fig. 4.2) 


Insert Retainer on top of Wiper making 

sure the sharp edge side is located on top 

(Fig. 4.3) 


Snap Ring (Fig. 4.4) 


Insert O-Ring on Lower Adjusting Screw 

and grease it (Fig. 4.5 and 4.6) 


Insert Upper Stem in Lower Adjusting 

Screw, being careful not to share O-Ring 

(Fig. 4.7) 

Tighten Lower Adjusting Screw on the bottom 

part of Yoke (Fig. 4.8) 


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HPMV ASSEMBLY 

STEP 5 


Place the Yoke on top of the Body (Fig. 

5.1) 

Insert Bolts and tighten them with a 

wrench (Fig. 5.2) 


Use a brush to grease the Upper Stem 

(Fig. 5.3) 


stem while tightening the Diaphragm Plate 

(Fig. 5.4 and 5.5) 


Grease the Pivot surface of the 


Insert Spring Plate in the Pivot Sleeve 

(Fig. 5.7) 


Insert Spring on Diaphragm Plate 

(Fig. 5.8) 

Insert Spring Plate on top of Spring 

(Fig. 5.9) 


Place the Bonnet on top of Yoke making 

sure the sure the Breather and the Supply 

holes are aligned (Fig. 5.10) 




HPMV ASSEMBLY 

Insert bolts on top of the Bonnet and tighten 

them with the impact gun (Fig. 5.11) 

Grease the Adjusting Screw (Fig. 5.12) 


Place the Pivot on top of the Adjusting 

Screw and grease the top part of the Pivot 

(Fig. 5.13 and 5.14) 


Screw the Adjusting Screw on top of 

Bonnet and tighten it with an adjustable 

wrench (Fig. 5.15 and 5.16) 

STEP 6 

BLOCK 

When you assemble the Block, make sure 

the bevels are in the same side of the 

block as show in (Fig. 6.1) 


Place the threaded Half Block on the back 

side (Fig. 6.2) 


Tighten the bolts in the Block with a 

socket (Fig. 6.3) 


the correct operation of the valve either 

PO or PC (Fig. 6.4) 


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HPMV TESTING 

EQUIPMENT & REQUIREMENTS 

SUPPLY PRESSURE: 100 psi 

SUPPLY CONNECTION: Device that will reduce your regulator end to any 

air supply connection. 

Fig. A shows an example of this device. It is important to have a valve in 

this device for testing purposes. 

STEP 7 

HPMV PO TESTING 

Apply air supply pressure (do not exceed 

45 psi) on Yoke (Fig. 7.1) This will open 

the valve and will pressurize the bottom 

part of the Diaphragm. 

Figure A 

Spray soaped solution on the Lower 

Adjusting Screw to check for any leakage 

(Fig. 7.2) 


Spray soaped solution on the Interface 

between the Bonnet and the Yoke. Check 

for leakage (Fig. 7.3) 

Figure 7.3 



NOTES 

Page 26 

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PISTON BALANCED DISASSEMBLY 

KIMRAY SEAT WRENCH W SERIES 

PART NUMBER LINE SIZE 

386SW 3" & 4" HPMVPB 

Note: Seat Wrench W Series are mainly used for Treater 

Valves, but they can be used to assemble the Diaphragm 

Nut for 3” and 4” High Pressure Motor Valves. 

Figure A 

UPPER CAGE PULLERS 


5296 2" HPMVPB 



6” Piston Assembly Puller 

Figure B 

Use this tool to lift the Piston Assembly out of the Body by 

pulling it with a hoist. 

Note: This is a shop made tool using a Coupling Block, 

Upper Stem and a ring. 

Figure C 




STEP 1 

ADJUSTING SCREW 

Use a wrench to remove the Adjusting 

Screw on top of the Bonnet (Fig. 1.1) 

STEP 2 

BONNET 

Remove the bolts in the interface between 

the Bonnet and the Yoke (Fig. 2.1) 

Figure 1.1 

Remove Breather Plug from Bonnet 

(Fig. 2.2) 


Remove Bonnet from Yoke (Fig. 2.3) 

STEP 3 

SPRING 

Remove Pivot and the Spring Plate from 

top of the Spring (Fig. 3.1) 

Figure 2.3 

Remove the spring from top Spring Plate 

(Fig. 3.2) 

STEP 4 


Spin the Diaphragm plate in a counter 

clock wise direction loosening it from the 

Upper Stem while holding the Upper Stem 

with a small crescent wrench (Fig. 4.1). 

Remove the Diaphragm Nut from the 




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STEP 5 

TRAVEL INDICATOR 

Remove the bolts from the Travel 

Indicator Block (Fig. 5.1) 

Remove the Coupling Block (Fig. 5.2) 

STEP 6 

YOKE ASSEMBLY 

Use a wrench to remove the bolts from 

Yoke (Fig. 6.1) 

Slide out the Yoke from Body (Fig. 6.2) 

Flip Yoke upside down and remove the 

Upper Stem from the Lower Adjusting 


Take a socket and remove the Lower 

Adjusting Screw with an impact gun 

(Fig. 6.4) 

Remove the outside O-Ring from the 


Remove O-Ring from the inside of the 







Remove the Retainer Washer (Fig. 6.8) 

Remove the Wiper from the Lower 



STEP 7 


Use an adjustable wrench to remove the 

Stuffing Box from the Body (Fig. 7.1 and 

7.2) 

Figure 6.9 


Remove Spring and Follower from Stuffing 

Box (Fig. 7.3) 

Remove the Packing Sleeve and the 

Packing Ring from the Stuffing Box 

(Fig. 7.4) 




Remove the Retainer Washer from the 



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Remove the Wiper from the Stuffing Box 

(Fig. 7.7) 

STEP 8 

UPPER HOUSING 

Use an impact gun to remove the bolts 

from the Upper Housing (Fig. 8.1) 

Figure 7.7 

Break the Upper Housing loose by prying 

up with screw drivers (Fig. 8.2) 

Remove the Upper Housing from the 

Body (Fig. 8.3). 


STEP 9 

PISTON ASSEMBLY 

Some times the Upper Cage will not break 

loose easy. If this is the case use an 

Upper Cage Puller. 

Start by removing the O-Ring from the 

Cage (Fig. 9.1) 

Slide Upper Cage Pullers in O-Ring 

groove on Cage and clamp with a water 

hose clamp (Fig. 9.2) 

Figure 8.3 


Alternately tighten screw until cage breaks 

loose from Body (Fig. 9.3) 

Figure 9.3 




Remove the Piston Assembly from Body 

(Fig. 9.4) 

Slide up Upper Cage from the Piston 

Assembly (Fig. 9.5) 

Remove the O-Ring and two Backups 

(Fig. 9.6) 

Remove the Lower Cage from Piston 

Assembly (Fig. 9.7) 



Use a socket to remove the screw that 

holds the Ratio Plug (Fig. 9.8) 

Remove the Ratio Plug (Fig. 9.9) 


Remove O-Rings from Piston Assembly 

(Fig. 9.10, 9.11 and 9.12) 


Figure 9.12 

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STEP 10 

SEAT 

Remove seat from Body (Fig. 10.1 & 10.2) 

Remove O-Ring from Seat (Fig. 10.3) 


Figure 10.3 



NOTES 

Page 34 

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PISTON BALANCED INSPECTION of PARTS 

PISTON ROD 

Replace: 

• If piston rod is bent (Fig. 1.1) 

PISTON 

Figure 1.1 

Replace: 

• If the parts present corrosion in the 

outside surface (Fig. 2.1) 

SEAT 

Figure 2.1 

Replace: 

• In the presence of dings, nicks or corrosion 

(Fig. 3.1) 

RATIO PLUG 

Figure 3.1 

Replace: 

• In the presence of scratches, corrosion 

and wear (Fig. 4.1) 

Note: This is one of the most affected 

parts due to the severe impact of the particles 

that flow trough the valve. 

CAGE 

Figure 4.1 

Replace: 

• If the Cage has lost its shape 

(Fig. 5.1) 

Note: If the valve was improperly disassembled, 

there is a high possibility to 

have a Cage out-of-round. 

Figure 5.1 



PISTON BALANCED INSPECTION of PARTS 

STUFFING BOX 

Replace: 

• In the presence of excessive corrosion 

and wear. (Fig. 6.1, 6.2 and 6.3) 

Note: Most of the times this part can be 

repair by cleaning and wire brushing the 

inside and outside threads. 

Figure 6.2 


Page 36 

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PISTON BALANCED ASSEMBLY 

KIMRAY SEAT WRENCH W SERIES 


386SW 3" & 4" HPMVPB 

Note: Seat Wrench W Series are mainly used for Treater 

Valves, but they can be used to assemble the Diaphragm 

Nut for 3" and 4" High Pressure Motor Valves. 

Figure A 

STEP 1 

SEAT 

Grease the seat surface inside the Body 

(Figure 1.1) 

Insert O-Ring on Seat and place it in Body 

(Fig. 1.2) 

STEP 2 

PISTON ASSEMBLY 

Insert O-Ring inside Piston Assembly 

(Fig. 2.1) 


Insert O-Ring in Ratio Plug (Fig. 2.2) 


Insert O-Ring with the angled side on top 

(Fig. 2.3 and 2.4) 


Insert Ratio Plug in the Piston Assembly 

(Fig. 2.5) 

Finger tighten the screw holding the Ratio 

Plug on Piston Assembly (Fig. 2.6) 





Use brass jaws to hold the Piston 

Assembly in vice (Fig. 2.7) 

Use a socket to tighten the Ratio Plug 


Insert Lower Cage on Piston Assembly 

(Fig. 2.9) 

Grease the Piston Assembly (Fig. 2.10) 



Insert Backup on Piston Assembly 

(Fig. 2.11) 

Insert O-Ring on Piston Assembly 

(Fig. 2.12) 


Insert Backup on Piston Assembly 

(Fig. 2.13) 

Grease O-Ring and Backups (Fig. 2.14) 

Insert two O-Rings in the Upper Cage 

grooves (Fig. 2.15 and 2.16) 



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Insert Piston Assembly Stem in to Upper 

Cage (Fig. 2.17). Press Upper Cage on to 

Piston Assembly. 

Grease O-Rings in Upper Cage (Fig. 2.18) 

Spray Never Seez in the Piston Assembly 

(Fig. 2.19) 

Insert Piston Assembly in Body (Fig. 2.20) 



Use a rubber hammer to press Piston 

Assembly in Body (Fig. 2.21) 

Use a rubber hammer to tap the Piston 

Assembly Rod pressing the Seat in place 

(Fig. 2.22) 

STEP 3 

UPPER HOUSING 

Insert Upper Housing on Body (Fig. 3.1). 

Make sure the Safety Relief Hole is facing 

tapped holes on Body. 


Insert bolts and tighten them in a crisscross 

pattern (Fig. 3.2) 

STEP 4 

STUFFING BOX 

Insert two wipers in Stuffing Box (Fig. 4.1) 


Insert Retainer Washer on top with the 

sharp edge side facing up (Fig. 4.2) 





Use a pair or snap ring pliers to insert the 

Snap Ring on top of the Retainer Washer 

(Fig. 4.3) 

Insert O-Ring on Stuffing Box (Fig. 4.4) 

Grease the Stuffing Box Hole (Fig. 4.5) 

Insert Packing Rings and Packing Sleeve 

in Stuffing Box, with the large blue end of 

sleeve down (Fig. 4.6). 



Insert Follower in Stuffing Box (Fig. 4.7) 

Insert Spring in Stuffing Box (Fig. 4.8) 


Fill the Stuffing Box with grease (Fig. 4.9) 

Spray Never Seez on the Stuffing Box 

(Fig. 4.10) 


Insert Stuffing Box in Upper Housing 

(Fig. 4.11) 

Tighten Stuffing Box with an adjustable 

wrench (Fig. 4.12) 


Page 40 

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STEP 5 

LOWER ADJUSTING SCREW 

Insert two Wipers in the Lower Adjusting 


Insert Retainer Washer with the sharp 

edge side facing up (Fig. 5.2) 



Snap Ring on top of the Retainer Washer 

(Fig. 5.3) 

Insert O-Ring inside the Lower Adjusting 


Insert O-Ring around the Lower Adjusting 



Grease O-Rings in Lower Adjusting Screw 

(Fig. 5.6) 


Insert Upper Stem in Lower Adjusting 


Note: Make sure you do not shear the O- 

Ring. 

Tighten Lower Adjusting Screw in Yoke 

(Fig. 5.8) 

STEP 6 

YOKE 

Insert Yoke on top of the Upper Housing 

(Fig. 6.1) 


Insert Bolts and tighten in a criss-cross 

pattern (Fig. 6.2) 





Insert Spring on Diaphragm Plate 

(Fig. 7.11) 

Insert the second Spring plate on top of 

Spring (Fig. 7.12) 


Grease the top side of the Spring Plate 

(Fig.7.13) 

Insert Pivot on top of the Spring Plate 

(Fig. 7.14) 


Place the Bonnet on top of Yoke 

(Fig. 7.15) 

Tighten the Breather Plug on top of the 



Insert bolts on the Bonnet and tighten in a 

criss-cross pattern (Fig. 7.17 and 7.18) 

Tighten the Upper Adjusting Screw on top 

of Bonnet (Fig. 7.19) 


Figure 7.19 




STEP 8 

COUPLING BLOCK 

Make sure the bevels are aligned in the 

Coupling Block (Fig. 8.1) 

Use an impact gun to tighten the screws 

in the Coupling Block (Fig. 8.2) 


the correct operation of the valve 

(Fig. 8.3) 


Figure 8.3 

Page 44 

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HIGH PRESSURE MOTOR VALVE REPAIR MANUAL 

NOTES 

www.kimray.com

High Pressure Motor Valves - Home | Kimray Mobile - Kimray, Inc.

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