To start, unthread the stuffing box assembly from the upper housing. Next, remove the upper housing bolts and lift the upper housing away from the body. If the upper housing is reluctant to come off, try using a flathead screwdriver or something similar to pry it away from the body. Now remove the cage and piston assembly from the body by pulling up on the stem.
If the stem does not come out easily by hand, try using the custom Kimray Cage Puller. To use this tool, remove the top O-ring on the cage assembly to be able to mount the cage puller. Tighten the bolts on the cage puller one at a time to lift the cage assembly out of the body. Once the cage and piston assembly are out of the body, check the area where the seat sets to make sure there is no abnormal wear corrosion.
Next, start disassembling the cage and piston assembly. Use a pipe wrench to grab hold of the cage and a custom Kimray Seat Removal tool to remove the seat. After removing the piston from the cage assembly, put it into the vice on the two machined flats directly above the piston. When the bolt is removed from the middle of the ratio plug, remove the plug itself along with the seat disc. Lastly, remove all the O-rings from the piston assembly. Now the valve is fully disassembled.
To begin installing the Kimray repair kit, start by installing the O-ring in between the piston and the seat disc. Next, mount the seat disc on top of the piston. Check to make sure the bevel side is facing up, then thread the ratio plug bolt through the ratio plug. Install the O-ring around the bolt, and then thread it into the piston.
The next step is to install the two outer rings on the cage, as well as the two backups and quad ring on the inside. Before beginning this next step, grease the two backups and the O-ring on the inside of the cage before installing the piston. Now install the piston into the cage.
Next, install the seal ring onto the seat. Now it’s possible to thread the seat onto the cage assembly. Apply a few dabs of grease on the bottom of the seat. This ensures that the O-ring stays in place and makes a good seal with the body. Also grease the outer rings.
Next, place the entire cage and piston assembly back into the valve body. Now mount the upper housing and align the bolt holes. Finally, make sure that the stuffing box assembly is packed full of grease so that it can thread back to the upper housing.
If you have any questions about this post or about the Kimray repair kit, reach out to your local Kimray representative.