RM0001 1

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 dont save you
money!!!
ENG-002.3 REV. 4 Issued 1-11-2012
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Page 1

ELASTOMERS
AFLAS
VITON
is a trade mark of Asahi Glass Co
is a trade mark of Dupont
TEMPERATURE:
-25 to +500 F
-30 to +260 C
TEMPERATURE:
-10 to +350 F
-23 to +177 C
APPLICATION:
Crude Oil & Gas Production (High heat), Steam
Flood Production Chemicals (corrosion inhibitors) Amine
Sweetener Systems, Gasoline, Diesel, Fuel Oil Systems
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 Production, H2S, Steam, Petroleum
fluids, Sea Water
HSN (Highly Saturated Nitrile)
FLUID / GAS:
Crude Oil & Gas, Sour Gas (C02), Propane, Gasoline,
Diesel, Fuel Oil Systems
DO NOT USE WITH:
Hot Water, Not preferred for wet H2S, Methyl Alcohol,
Amines, Sodium hydroxide solutions
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
NITRILE
TEMPERATURE:
Buna-N:
-40 to +220 F
-40 to +105 C
Low-Temp:
-85 to +120 F
-65 to +49 C
ETHYLENE PROPYLENE
TEMPERATURE:
-65 to +300 F
-54 to +148 C
APPLICATION:
Steam Flood
FLUID / GAS:
Steam, Water, Alcohol
DO NOT USE WITH:
Crude Oil & Gas, Diester Lubricants (Lube Oils)
POLYURETHANE
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
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
POLYACRYLATE
DO NOT USE WITH:
Aromatic hydrocarbons, chlorinated hydrocarbons,
phosphate esters (hydraulic fluids)
GYLON
TEMPERATURE:
0 to +300 F
-17 to +149 C
TEMPERATURE:
-350 to +500 F
APPLICATION:
Production Heaters, Thermostats
APPLICATION:
High heat, high chemical resistance, highly resistance
to gas permeation
FLUID / GAS:
Crude Oil & Gas at High Temperature
DO NOT USE WITH:
Alcohol, Glycols
Page 2
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MATERIALS
Standard materials in the standard Kimray High Pressure Motor Valve include:
Exterior Parts:
Bonnet
Body
Ductile Iron ASTM - A395

Cast Steel ASTM - A216 WCB
Interior Parts:
Stem
Cage
Stuffing Box
Seat
Plug
303 Stainless Steel

Free Machining Steel AISI 12L14
Tool Steel AISI D2
Carbide/303 Stainless
Elastomers:
Packing
O-Rings
Diaphragm
Nitrile/Teflon
Nitrile
Nitrile
Standard materials in the Kimray Piston Balanced High Pressure Motor Valve include
Exterior Parts:
Bonnet:
Body
Ductile Iron ASTM - A395

Cast Steel ASTM - A216 WCB
Interior Parts:
Upper Housing
Stem
Cage
Stuffing Box
Seat
Piston
Steel AISI C1018

316 Stainless Steel
316 Stainless Steel
Tool Steel AISI D2
Tool Steel AISI D2
Elastomers:
Packing
O-Rings
Diaphragm
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 dont save you
money!!!
www.kimray.com
Page 3

NOTES
Page 4
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PRESSURE OPEN TO PRESSURE CLOSE CONVERSION
STEP 1
BLOCK DISASSEMBLY
Start from disassembling the Travel
Indicator Block (Fig. 1.1)
Figure 1.1
STEP 2
BREATHER PLUG
Remove the breather plug from the
Bonnet (Fig. 2.1)
Figure 2.1
STEP 3
ADJUSTING SCREW
Remove the Adjusting Screw from top of
Bonnet (Fig. 3.1)
Figure 3.1
STEP 4
PIVOT
Remove Pivot from Adjusting Screw
(Fig. 4.1)
Figure 4.1
STEP 5
BONNET
Remove the Bonnet by loosing the bolts
(Fig. 5.1 and 5.2)
Figure 5.1
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Figure 5.2
Page 5

STEP 6
SPRING
Remove the Spring from the Diaphragm
Plate (Fig. 6.1)
Figure 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)
Remove the Diaphragm Plate from the

Yoke (Fig. 7.3)
Figure 7.1
Figure 7.2
Figure 7.3
STEP 8
RETRIEVING O-RING
NOTE: THIS STEP SHOULD BE
FOLLOWED 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 8.1
Figure 8.2
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
Page 6
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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)
Figure 9.1
Figure 9.2
Figure 9.3
Figure 9.4
Figure 9.5
Figure 9.6
Figure 9.7
Figure 9.8
Figure 9.9
Figure 9.10
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
Bonnet (Fig. 9.10)
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Page 7

STEP 10
BREATHER PLUG
Insert Breather plug on Yoke (Fig. 10.1)
Figure 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)
Place the threaded half Block on back
side (Fig 11.2)
Figure 11.1
Figure 11.2
Figure 11.3
Figure 11.4
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
Page 8
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HPMV DISASSEMBLY
KIMRAY TOOLS
Seat Pullers
Figure A shows the Kimrays Seat & Cage
Removal Tool. The handles flange the
disc to the body while pulling the seat or
cage.
Figure B shows a Kimrays Seat Removal
Tools able to remove the seat from body
when the cage has been removed.
Figure A
Figure B
KIMRAY SEAT & CAGE

REMOVAL TOOL
KIMRAY SEAT
REMOVAL TOOL
PART #
LINE SIZE
PART #
LINE SIZE
3032
1"
615
1"
3033
2"
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)
Figure 1.1
Figure 1.2
Figure 2.1
Figure 2.2
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
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Page 9

HPMV DISASSEMBLY
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)
Figure 3.1
Figure 3.2
Remove the spring from top Spring Plate

(Fig. 3.3)
Figure 3.3
STEP 4
DIAPHRAGM PLATE
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)
Figure 4.1
Figure 4.2
Figure 4.3
Figure 4.4
Figure 4.5
Figure 4.6
Remove the Diaphragm Nut from the

Remove the Diaphragm from the
THREADED DIAPHRAGM NUT:

Use a pair of pliers to remove the
Diaphragm Nut (Fig. 4.5)
Page 10
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HPMV DISASSEMBLY
STEP 5
TRAVEL INDICATOR
Remove the bolts from the travel Indicator
Block (Fig. 5.1)
Remove the Block from stem (Fig. 5.2)
Figure 5.1
Figure 5.2
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 6.6
Figure 6.7
Figure 6.8
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)
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Page 11

HPMV DISASSEMBLY
Remove the Retainer washer (Fig. 6.9)

Remove the Wiper from the Lower
Figure 6.9
Figure 6.10
Figure 7.1
Figure 7.2
Figure 7.3
Figure 7.4
Figure 7.5
Figure 7.6
Figure 7.7
Figure 7.8
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 doesnt 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)
Page 12
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HPMV DISASSEMBLY
Remove the Cage from the Ball and Stem

(Fig. 7.9)
Remove O-Ring from the Seat (Fig 7.10)
Figure 7.9
Figure 7.10
Figure 7.11
Figure 7.12
Figure 7.13
Figure 7.14
Figure 7.15
Figure 7.16
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
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Page 13

HPMV DISASSEMBLY
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
Figure 8.2
Second Option:
If the Stuffing Box comes out by it self
leaving seat, Ball & Stem and Cage stuck
in Body.
1.

2.
3.

Thread Seat & Cage Removal Tool

on to Cage (Fig. 8.3)
Tighten flange down against Body
Pull Case and Seat out of Body
(Figure 8.4)
Figure 8.3
Figure 8.4
The other end of the tool is used in case

just the Seat stays in Body.(Fig. 8.5)
1.

2.
3.

Thread Seat & Cage Removal Tool

on seat
Tighten flange against Body
Pull the seat out by turning the
handle in a clock wise direction
Figure 8.5
Page 14
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HPMV DISASSEMBLY
SHOP MADE SEAT REMOVAL TOOL

This seat removal tool can be made with the
following parts:
QTY
PART
DESCRIPTION
2889
Cage
2837
Cage
Stops
Disc 1 3/4" x 3/4"
Rod
1 3/8" x 22"
Handle
11 3/4" od. x 3/8" id. x 5 1/2" lg.
22"
3"
3/4"
PART 2889
3/8"
2 1/2"
5 1/2"
1 3/4"
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.
Figure 9.3
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Figure 9.4
Page 15

NOTES
Page 16
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HPMV INSPECTION of PARTS
MOST COMMONLY REPLACED PARTS

OCCASIONALLY CHANGED PARTS

Seat Body

Stem & Ball Spring

Diaphragm

O-Rings

Packing
BALL & STEM

Check for scratches
Replace:
If there are scratches present
(Fig. 1.1)
Figure 1.1
SEAT
Replace:
If the seat has indication of leakage
(Fig 2.1)
Figure 2.1
BODY
Replace:
If grooves are present on the seating
surface (Fig.3.1)
Figure 3.1
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Page 17

NOTES
Page 18
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HPMV ASSEMBLY
STEP 1
DIAPHRAGM ASSEMBLY
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)
Figure 1.1
Figure 1.2
Figure 1.3
Figure 1.4
Figure 1.5
Figure 1.6
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.
Figure 1.7
STEP 2
Insert Wiper in the Stuffing Box (Fig. 2.1)
Insert the retainer with the sharp edge on
top (Fig. 2.2)
Figure 2.1
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Figure 2.2
Page 19

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)
Figure 2.3
Figure 2.4
Figure 2.5
Figure 2.6
Figure 2.7
Figure 2.8
Figure 2.9
Figure 2.10
Figure 2.11
Figure 2.12
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)
Page 20
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HPMV ASSEMBLY
Insert O-Ring on Seat (Fig. 2.13)

Introduce the Stem in Cage (Fig. 2.14)
Figure 2.13
Figure 2.14
Figure 2.15
Figure 2.16
Figure 2.17
Figure 2.18
Figure 2.19
Figure 2.20
Figure 3.1
Figure 3.2
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)
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Page 21

HPMV ASSEMBLY
BODY TESTING:
Apply air pressure on the upstream side of
the valve (Fig. 3.3)
Test for leakage in the downstream side
Figure 3.3
STEP 4
LOWER ADJUSTING SCREW
Insert O-Ring in the Lower Adjusting
Screw (Fig. 4.1)
Flip the Lower Adjusting Screw over and
insert Wiper (Fig. 4.2)
Figure 4.1
Figure 4.2
Figure 4.3
Figure 4.4
Figure 4.5
Figure 4.6
Figure 4.7
Figure 4.8
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)
Page 22
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HPMV ASSEMBLY
STEP 5
DIAPHRAGM ASSEMBLY
Place the Yoke on top of the Body (Fig.
5.1)
Insert Bolts and tighten them with a
wrench (Fig. 5.2)
Figure 5.1
Figure 5.2
Figure 5.3
Figure 5.4
Figure 5.5
Figure 5.6
Figure 5.7
Figure 5.8
Figure 5.9
Figure 5.10
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)
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Page 23

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)
Figure 5.11
Figure 5.12
Figure 5.13
Figure 5.14
Figure 5.15
Figure 5.16
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
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)
Page 24
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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.
Figure A
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.
Spray soaped solution on the Lower
Adjusting Screw to check for any leakage
(Fig. 7.2)
Figure 7.1
Figure 7.2
Spray soaped solution on the Interface

between the Bonnet and the Yoke. Check
for leakage (Fig. 7.3)
Figure 7.3
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Page 25

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

PART NUMBER
LINE SIZE
5296
2" HPMVPB
5297
3" HPMVPB
5298
4" HPMVPB
Figure B
6 Piston Assembly Puller

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
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Page 27

STEP 1
ADJUSTING SCREW
Use a wrench to remove the Adjusting
Screw on top of the Bonnet (Fig. 1.1)
Figure 1.1
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)
Figure 2.1
Figure 2.2
Remove Bonnet from Yoke (Fig. 2.3)
Figure 2.3
STEP 3
SPRING
Remove Pivot and the Spring Plate from
top of the Spring (Fig. 3.1)
Remove the Spring from top Spring Plate
(Fig. 3.2)
Figure 3.1
Figure 3.2
Figure 4.1
Figure 4.2
STEP 4
DIAPHRAGM PLATE
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
Page 28
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Figure 4.3
STEP 5
TRAVEL INDICATOR
Remove the bolts from the Travel
Indicator Block (Fig. 5.1)
Remove the Coupling Block (Fig. 5.2)
Figure 5.1
Figure 5.2
Figure 6.1
Figure 6.2
Figure 6.3
Figure 6.4
Figure 6.5
Figure 6.6
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
Screw (Fig. 6.3)
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
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Page 29


Remove the Retainer Washer (Fig. 6.8)
Figure 6.7
Figure 6.8
Remove the Wiper from the Lower

Figure 6.9
STEP 7
Use an adjustable wrench to remove the
Stuffing Box from the Body (Fig. 7.1 and
7.2)
Figure 7.1
Figure 7.2
Figure 7.3
Figure 7.4
Figure 7.5
Figure 7.6
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
Page 30
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Remove the Wiper from the Stuffing Box

(Fig. 7.7)
Figure 7.7
STEP 8
UPPER HOUSING
Use an impact gun to remove the bolts
from the Upper Housing (Fig. 8.1)
Break the Upper Housing loose by prying
up with screw drivers (Fig. 8.2)
Remove the Upper Housing from the Body

(Fig. 8.3).
Figure 8.1
Figure 8.2
Figure 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 9.1
Figure 9.2
Alternately tighten screw until cage breaks

loose from Body (Fig. 9.3)
Figure 9.3
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Page 31

Remove the Piston Assembly from Body

(Fig. 9.4)
Slide up Upper Cage from the Piston
Assembly (Fig. 9.5)
Figure 9.4
Figure 9.5
Figure 9.6
Figure 9.7
Figure 9.8
Figure 9.9
Figure 9.10
Figure 9.11
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)
Figure 10.1
Figure 10.2
Remove O-Ring from Seat (Fig. 10.3)
Figure 10.3
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Page 33

NOTES
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PISTON BALANCED INSPECTION of PARTS
PISTON ROD
Replace:
If piston rod is bent (Fig. 1.1)
Figure 1.1
PISTON
Replace:
If the parts present corrosion in the
outside surface (Fig. 2.1)
Figure 2.1
SEAT
Replace:
In the presence of dings, nicks or co rrosion (Fig. 3.1)
Figure 3.1
RATIO PLUG
Replace:
In the presence of scratches, corro sion 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.
Figure 4.1
CAGE
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
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Page 35

PISTON BALANCED INSPECTION of PARTS
STUFFING BOX
Replace:
In the presence of excessive corro sion 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
Figure 6.1
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Figure 6.3

PISTON BALANCED ASSEMBLY

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
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)
Figure 1.1
Figure 1.2
Figure 2.1
Figure 2.2
Figure 2.3
Figure 2.4
Figure 2.5
Figure 2.6
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)
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Page 37

Use brass jaws to hold the Piston

Assembly in vice (Fig. 2.7)
Use a socket to tighten the Ratio Plug
Screw (Fig. 2.8)
Figure 2.7
Figure 2.8
Figure 2.9
Figure 2.10
Figure 2.11
Figure 2.12
Figure 2.13
Figure 2.14
Figure 2.15
Figure 2.16
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)
Page 38
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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)
Figure 2.17
Figure 2.18
Figure 2.19
Figure 2.20
Figure 2.21
Figure 2.22
Figure 3.1
Figure 3.2
Figure 4.1
Figure 4.2
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)
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Page 39

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)
Figure 4.3
Figure 4.4
Figure 4.5
Figure 4.6
Figure 4.7
Figure 4.8
Figure 4.9
Figure 4.10
Figure 4.11
Figure 4.12
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
Screw (Fig. 5.1)
Insert Retainer Washer with the sharp
edge side facing up (Fig. 5.2)
Figure 5.1
Figure 5.2
Figure 5.3
Figure 5.4
Figure 5.5
Figure 5.6
Figure 5.7
Figure 5.8
Figure 6.1
Figure 6.2

Snap Ring on top of the Retainer Washer
(Fig. 5.3)
Insert O-Ring inside the Lower Adjusting
Screw (Fig. 5.4)
Insert O-Ring around the Lower Adjusting

Screw (Fig. 5.5)
Grease O-Rings in Lower Adjusting Screw
(Fig. 5.6)
Insert Upper Stem in Lower Adjusting

Screw (Fig. 5.7)
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)
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Page 41

STEP 7
DIAPHRAGM ASSEMBLY
Use a pair of brass jaws to hold the
Diaphragm Plate in a vice (Fig. 7.1)
Grease the Diaphragm Plate inside perimeter (Fig. 7.2)
Figure 7.1
Figure 7.2
Figure 7.3
Figure 7.4
Figure 7.5
Figure 7.6
Figure 7.7
Figure 7.8
Figure 7.9
Figure 7.10
Place Diaphragm on Diaphragm Plate

(Fig. 7.3)
Thread Diaphragm Nut on Diaphragm
Plate (Fig. 7.4)
Use a 386SW Seat Wrench W Series to

tighten the Diaphragm Nut (Fig. 7.5)
Note: Make sure the Diaphragm does not
wrinkle.
Grease the top hole of the Diaphragm
Plate (Fig. 7.6)
Insert Diaphragm Plate Assembly on top

of Yoke (Fig. 7.7)
Use an adjustable wrench to hold
the Upper Stem while tightening the
Grease the Sleeve on the Diaphragm

Plate (Fig. 7.9)
Insert the Spring Plate in Diaphragm Plate
(Fig. 7.10)
Page 42
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Insert Spring on Diaphragm Plate

(Fig. 7.11)
Insert the second Spring plate on top of
Spring (Fig. 7.12)
Figure 7.11
Figure 7.12
Figure 7.13
Figure 7.14
Figure 7.15
Figure 7.16
Figure 7.17
Figure 7.18
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
Bonnet (Fig. 7.16)
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
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Page 43

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)
Figure 8.1
Figure 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
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Repair Manual

High Pressure Motor Valves

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

HIGH PRESSURE MOTOR VALVE REPAIR MANUAL

ENG-002.3 REV. 4 Issued 1-11-2012

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

is a trade mark of Asahi Glass Co

is a trade mark of Dupont

HSN (Highly Saturated Nitrile)

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Ductile Iron ASTM - A395

303 Stainless Steel

Ductile Iron ASTM - A395

Steel AISI C1018

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Remove the Diaphragm Plate from the

Use a pick remove the O-Ring from the

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Insert the Spring on top of the Spring

Insert the Diaphragm Plate on top of the

Use an adjustable wrench to hold the

Insert O-Ring on the Upper Adjusting

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Tighten the bolts in the Coupling Block

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

KIMRAY SEAT & CAGE

Remove Bonnet from Yoke (Fig. 2.3)

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Remove the spring from top Spring Plate

Remove the Diaphragm Nut from the

THREADED DIAPHRAGM NUT:

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Flip the Yoke upside down, then take a

Slide out the Upper Stem from the Lower

Remove O-Ring from the inside of the

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Remove the Retainer washer (Fig. 6.9)

Clamp the two flat sides of the Stuffing

Remove Cage and Stem from the Stuffing

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Remove the Cage from the Ball and Stem

Remove O-Ring from Stuffing Box (Fig.

Remove the Packing Rings from the

Use a pair of snap ring pliers to remove

Remove the Wiper from the Stuffing Box

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

Thread Seat & Cage Removal Tool

The other end of the tool is used in case

Thread Seat & Cage Removal Tool

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

SHOP MADE SEAT REMOVAL TOOL

Disc 1 3/4" x 3/4"

11 3/4" od. x 3/8" id. x 5 1/2" lg.

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

Slide Handle forcefully upwards until you

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

MOST COMMONLY REPLACED PARTS

BALL & STEM

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL

HIGH PRESSURE MOTOR VALVES REPAIR MANUAL