INSTALLATION

OPERATION &
MAINTENANCE

GUIDE

PRESSURE REGULATOR
PILOT OPERATED
All Rights Reserved.
All contents of this publication including illustrations are believed to be
reliable. And while efforts have been made to ensure their accuracy, they
are not to be construed as warranties for guarantees, express or implied,
regarding Kimray products or services described herein or their use or
application. All sales are governed by our terms and conditions, which are
available on request.

Kimray reserves the right to modify or improve the designs or specifications

of such products at any time without prior notice.

©2015 Kimray Inc.

 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

Contents
A Before you start...................................................... 4 17 Breather Plugs..................................................... 27
A1 Scope.................................................................4
A2 Introduction........................................................4 18 Adjusting Screw, Tubing..................................... 28
A3 Description.........................................................4
A4 Maintenance......................................................4 19 Guage.................................................................... 29
A5 Changes and Updates.......................................4
A6 Special Tools and Equipment............................. 5 TESTING
A7 Orientation.........................................................6

INSTALLATION 20 Flow Direction, Adjusting Screw, Check for

1 Installation.............................................................. 7 Leakage............................................................... 30

2 Start-up and Test.................................................... 7

DISASSEMBLY

3 Adjusting Screw, Tubing, Guage.......................... 8

4 Bonnet, Spring....................................................... 9

5 Diaphragm Housing Assembly........................... 10

6 Filter...................................................................... 12

7 Lower Seat............................................................ 13

8 Upper Housing..................................................... 13

9 Lower Housing Body........................................... 14

INSPECTION

10 Inspection & Cleaning......................................... 16

ASSEMBLY

11 Lower Housing Assembly................................... 19

12 Diaphragm............................................................ 21

13 Upper Housing, Lower Seat................................ 22

14 Filter...................................................................... 23

15 Diaphragm Plate.................................................. 24

16 Spring, Bonnet..................................................... 26

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide
A Before you start

CAUTION: CAUTION:
The instructions provided herein should be completely When ordered, the pressure regulator configuration and
reviewed and understood before operating or repairing construction materials were selected to meet specific
this equipment. All CAUTION and WARNING notes pressure, temperature, pressure drop and fluid conditions.
must be strictly observed to prevent personal injury or Since some body / trim material combinations are limited
equipment damage. in their pressure drop and temperature ranges, do not
subject the pressure regulator to any other conditions
A1 Scope without first contacting the Kimray Inc, sales office or a
sales / applications representative.
Do not install, operate, or maintain a pressure
regulator without being fully trained and qualified with the
Kimray installation, operation and maintenance manual.
WARNING:
To avoid personal injury or property damage, it is DO NOT exceed the maximum pressure specified on the
important to carefully read, understand, and follow all the nameplate. Under no circumstances should the regulator
contents of this manual, including all safety cautions and supply pressure ever exceed the maximum psig.
warnings.
A4 Maintenance
If you have any questions about this manual, contact your
Kimray applications support group before proceeding. Maintenance should be performed on a regular basis.
Initial intervals of 12 months is recommended. The
A2 Introduction maintenance interval may increase or decrease
depending on changing application environments. The
This repair manual contains information for the BP, BPNV, valve can be repaired without being removed from the
LBP, pressure regulators. piping.

A3 Description Related Publications

The following publications are applicable for the regulator
The Kimray back pressure regulator combines a pressure Number Type Title
pilot with a control valve. Except where liquid or very low
gas pressure is involved, upstream gas is used to oper-
ate the valve. In the pilot, a spring is compressed with See catalog section A for product pages.
an adjusting screw. This places a force against a thick
diaphragm which is in contact with the controlled pressure Abbreviations / Acronyms
on the side opposite of the spring. As the two forces work The abbreviations that follow are used in this manual.
against each other, they continually reposition a small Term Definition
three-way valve (the pilot plug and seats) which controls BP Back Pressure
diaphragm pressure in the valve. Proper function can BPNV Back Pressure Non Vent
best be accomplished when the gas flowing through the LBP Liquid Back Pressure
pilot is clean and free of liquid. The valve shuts off with a
resilient seat on the plug closing against a metal seat in Commonly Replaced Parts
the valve body. • Trim Set
• Diaphragm
The Kimray back pressure regulator maintains a constant • O-ring
upstream pressure. It limits upstream pressure by
adjusting open to relieve excess pressure or conserves Occasional Replacement Parts
upstream pressure by adjusting closed to limit the flow to • Body
downstream. • Spring

A5 Changes and Updates

NOTE:
To prevent galling or seizing at assembly level for straight
threads Kimray recommends using a nickel impregnated
paste. For other threads use a nickel impregnated PTFE
thread sealant tape.

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide
SPECIAL TOOLS AND EQUIPMENT

1/2" Trim 1" Trim

Seat Removal
Not Needed
1" Valve Tool
Connection
Stem Guide 1851
Stem Guide 1851 thru 1855
1" Trim 2" Trim Seat Removal Tool 272SW thru 275SW

Seat Removal
Not Needed 6945SW or 272SW
2" Valve Tool
Connection
Stem Guide 1852
Seat Removal Tool 6945SW
1-5/8" Trim 3" Trim

Seat Removal Ductile - 1219SW 6946SW

3” Valve Tool Steel - 1219HTSW or 273SW
Connection
Stem Guide 1853
Seat Removal Tool 6946SW
2" Trim 4" Trim

Seat Removal Ductile - 1220SW 6947SW

4” Valve Tool Steel - 1220HTSW or 274SW
Connection
Stem Guide 1854 Seat Removal Tool 1219HTSW

Seat Removal Tool 6947SW

3" Trim 6" Trim

Seat Removal Ductile - 1221SW 6948SW

6” Valve Tool Steel - 1221HTSW or 275SW
Connection
Stem Guide 1855
Seat Removal Tool 6948SW
Seat Removal Tool 1219SW

POWER TUBE BRUSH

Diameter Wire Size Length Stem Diameter

SIZE / SEAT TORQUE
1/4 in. 0.004 in. 3 1/2 in. 1/8 in.
2" Valves / 272K 30 FT-LB
3/4 in. 0.006 in. 3 1/2 in. 1/4 in.
3" Valves / 273K 80 FT-LB
1 1/4 in. 0.008 in. 3 1/2 in. 1/4 in.
4" Valves / 274K 80 FT-LB
NOTE: Standard Non-Kimray Tube Brushes
6" Valves / 275K 300 FT-LB

Tip:
Kimray recommends using the above
special tools and equipment for
disassembly, assembly and new part
replacements.

A6

Kimray reserves the right to modify or improve the special tools and equipment designs or specifications at anytime without notice.

www.kimray.com 5
PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ORIENTATION
1

2
3
4 22 37
5 39
35
23

6
24
7 25

17 26
8 18 40

9 27
36
19
10 32

11 28
20
12 29 33

39 21
13 30
31 34
14
15 38
16

A7
✴ Recommended spare parts and stocked as repair kits
See catalog section A for additional information
Item Description Qty Item Description Qty Item Description Qty
1 Adjusting Screw 1 16 Seat * 1 31 Body 1
2 Nut 1 17 Seat * 1 32 Gauge 1
3 Washer 1 18 Gasket * 1 33 Filter 1
4 Packing Seal 1 19 Housing 1 34 Tubing 1
5 Bonnet 1 20 Diaphragm * 1 35 Breather Plug 1
6 Spring Plates 2 21 Plate 1 36 Breather Plug 1
7 Spring 1 22 Housing 1 37 Breather Plug 1
8 Plate 1 23 Gasket * 1 38 Plug 1
9 Diaphragm Ring * 1 24 Back Up’s * 2 39 Screws 4
10 Diaphragm * 1 25 O-Ring * 1 40 Screws 8
11 Spring * 1 26 Stem 1
12 Nut 1 27 Disk 1
13 Housing 1 28 Seat * 1
14 Plug * 1 29 Ratio Plug 1
15 Diaphragm * 1 30 Lock Nut * 1

Kimray reserves the right to modify or improve the designs or specifications of such products at anytime without notice.
6 www.kimray.com
 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide
1 Installation
Before installing the pressure regulator, inspect it for shipment Back Pressure Regulator:
damage and for foreign material that may have collected during Remove the tapered plug after the regulator is installed. The
shipment. Inspect the openings in the valve and clean the pipe plug only prevents the oil from leaking out of the regulator during
lines to remove scale, chips and debris. shipment and installation.

1. Install the regulator with the arrow on the body pointing in the
direction of flow. The arrow indicates that the direction of flow
and will not necessarily prevent flow in the opposite direction.

2. Install the valve using good piping practice. For flanged

bodies remove the masking sticker from the raised face of each
end connection & use a suitable gasket between the body and
the pipeline flanges. For threaded (NPT) bodies, use TFE Tape
or pipe thread sealant on external pipe threads.

WARNING: Fig. 1-2

Regulators rated to 175 psig (12 bar), if hazardous or flammable Remove
gas is being conveyed and the regulator is in an enclosed Tapered Plug
See Fig. 1-2
area, personal injury or property damage could result from
accumulated gas being released through the vent. To avoid
potential risk, provide adequate ventilation or pipe away the
vented gas.
This does not apply to non venting NV models. No gas is
vented with NV.
Verify all pressure connections are tight before pressurizing the
system.
Fig. 1-1

NOTE:
Always check fastener tightness prior to valve installation,
2 Start-up and Test
testing, and use, as fasteners have the potential to loosen
in transit. This is recommended to ensure your safety and
proper valve function. NOTE:
*Kimray assembly torque method below* All regulators are tested after they are assembled at Kimray, but
they are not pre-set to a specific setpoint. The best practice for
8 4 obtaining a specific setpoint is to do so upon installation in the
1 3 desired application.
1 6
With the installation completed and appropriate relief and
check valves installed and set, slowly open the upstream and
5 2 downstream shutoff valves. Turn the adjusting screw out and
4 2 then back in until you feel it begin to meet resistance as it
3 7 engages the spring.
As you turn the adjusting screw clockwise, the set point
Four Bolt Eight Bolt pressure will increase.
9 5
6 1 14
16 3 WARNING:
1 4
8 12 Before any service, be certain that the valve is fully isolated
and that all pressure upstream and downstream has been
11 7 relieved. Use bypass valves or fully shut off the process. Be
3 2 sure that any operating or instrument gas lines has been
4 15
5 13 2 disconnected. Never assume that a check valve is fully blocking
6 10 the downstream line. Never tighten any fitting or the main
Six Bolt Sixteen Bolt connections to the regulator while there is pressure on the line.
A leaking valve indicates that service is required. Failure to take
the valve out of service immediately may create a hazardous
NOTE: condition.
Never stand directly over or in front of a regulator when the
system is pressurized. The regulator could suddenly open,
blowing debris onto the face and eyes. Check all vents
periodally to be certain they are clear.
If a vent should become blocked the regulator could loose
control.

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY
3 Adjusting Screw, Tubing, Gauge

Use an adjustable wrench to remove the adjusting

screw on top of the regulator. See Fig. 3-1

Remove tubing. See Fig. 3-2

Use pliers as a Back Up on filter then remove the

gauge with a wrench. This avoids breaking the
nipple in housing. See Fig. 3-3

Fig. 3-2

Adjusting
Screw

Washer

Packing
Seal

Fig. 3-1 Fig. 3-3

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY
4 Bonnet, Spring

Loosen the top screws to remove the Bonnet.

Pry bonnet loose with a flat head screwdriver.

See Fig. 4-1

Remove the spring and (2) plates. See Fig. 4-2

Spring Plate

Spring

Spring Plate

Bonnet

Fig. 4-2

Fig. 4-1

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY
5 Diaphragm Housing Assembly

Pry up the Housing with a screwdriver. See Fig. 5-1

Flip the Housing over and remove the Pilot Seat with
a 9/16 in. socket or wrench. See Fig. 5-2

Remove the Diaphragm.

Remove the Pilot Plug.

Flip the Housing over and remove the sense

Diaphragm Assembly. See Fig. 5-3

Pilot Plug ✴

Diaphragm ✴

Pilot Seat ✴

Fig. 5-2
Housing

Sense Diaphragm
Assembly
Remove
Diaphragm
Ring

Fig. 5-3

Fig. 5-1

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY

Remove the Spring from the Diaphragm Nut with

needle nose pliers

Use pliers to remove the Diaphragm Nut from the

Diaphragm Plate.
See Fig. 5-4
Spring ✴

Remove the Diaphragm from the Diaphragm Plate. Diaphragm

Nut ✴
See Fig. 5-5

Diaphragm✴

Fig. 5-4
Diaphragm✴

Diaphragm Plate

Fig. 5-5

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY
6 Filter

Remove the Filter Cap with an adjustable wrench, impact

gun or socket.

If the Filter Cap is too tight, tap the Filter Cap with a
hammer.

Remove the o-ring from the Filter Cap by using needle

nose pliers or a pick.

Use a slender screw driver and needle nose pliers to

remove the six filter screens from the inside.
See Fig. 6-1

Filter Cap
✴
O-ring

✴
Filter Screens
6 Req'd.

Use brass jaws

to protect the
filter housing

Fig. 6-1

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY
7 Lower Seat

Remove Lower Seat with a socket.

See Fig. 7-1

Use Screw
Seat and Driver Here
Gasket ✴

Fig. 7-1 Fig. 8-1

8 Upper Housing Diaphragm✴

Remove the bolts on the Upper Housing. Use a flat head

screw driver and wedge between Upper Housing breather
hole and nipple on Housing. Tap the screw driver with a
hammer and remove the Housing. See Fig. 8-1

Use a socket to remove the Breather Plug.

Use Screw
Driver Here
Remove Diaphragm. See Fig. 8-2

Use a flat head screw driver and wedge between breather

hole and nipple on Housing. Tap the screw driver with a
hammer and remove the Upper Housing.

Fig. 8-2

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY
9 Lower Housing, Body

NOTE:
Be sure the oil has been drained from the lower Housing.

Use a flat screw driver and wedge it between breather

hole nipple in Lower Housing and Body. Tap screw driver
with a hammer and remove Lower Housing. See Fig. 9-1

Flip Lower Housing over and remove the Diaphragm

Plate. See Fig. 9-2

Remove the Stem along with the Disc, Seat, Ratio Plug
and Lock Nut. See Fig. 9-3

Diaphragm
Plate

Lower
Housing
Fig. 9-2

✴ Lock Nut
Ratio Plug

Disc

Body

Stem

Fig. 9-1 Fig. 9-3

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

DISASSEMBLY

Insert brass jaws on vice (not shown). Tighten the Stem

in the vice and remove Lock Nut. See Fig. 9-4

Remove the Seat and Ratio Plug from the Disc.

Remove the O-ring and two Back Ups from the Lower
Housing. See Fig. 9-5

CAUTION:
Use putty knife to remove the Gasket from the body.
See Fig. 9-6
Back up✴ O-ring✴
✴
Gasket

Lock Nut ✴

Ratio Fig. 9-5

Plug

Seat ✴

Seat
Disc

Stem

Use brass jaws

to protect the
stem

Fig. 9-4 Fig. 9-6

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

INSPECTION
10 Inspection & Cleaning

11

3
12

13

5
10
6 7 8 14

Fig. 10-1

Item numbers 1-15 should be sandblasted or cleaned

Item Description Qty
1 Bonnet 1
2 Spring Plates 2
3 Spring 1
4 Diaphragm Plate 1
5 Diaphragm Nut 1
6 Housing 1
7 Nipple 1
8 Filter 1
9 Housing 1
10 Plate 1
11 Housing 1
12 Disk 1
13 Ratio Plug 1
14 Body 1

Kimray reserves the right to modify or improve the designs or specifications of such products at any time without notice.

16 www.kimray.com
 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

INSPECTION

Diaphragm Plate: Cleaning

Wire brush to clean the diaphragm
plate. See Fig. 10-2

Use an air nozzle to blow out the

particles from inside.

NOTE:
It is important to get every part of the filter clean. Any
loose particles left inside could cause leakage in the pilot
plug.
Fig. 10-2
Filter Cleaning:
Wire brush the Filter hole. See Fig. 10-3

Use an air nozzle to blow out the

particles from inside.

NOTE:
It is important to get every part of the Upper Housing
clean. Any loose particles left inside could cause leakage
in the Pilot Plug. See Fig. 10-4.

Filter: Cleaning
Wire brush the filter holes in the Upper
Housing.

Use an air nozzle to blow out the Fig. 10-3

particles from inside.

Flip Housing over and verify that communication hole

is clear and free of debris.
Communication
Hole

Fig. 10-4

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

INSPECTION

NOTE:
Nicks or fragments of gasket material can cause
misalignment on the body surface. This can be repaired
by using a flat file. See Fig. 10-5

Repair:
If there are dings in the Lower Housing.

Cleaning:
Wire brush both the breather hole and
the Lower Housing. See Fig. 10-6
Fig. 10-5
Use an air nozzle to blow out the
particales from inside the Lower Housing.

NOTE:
Roll the Stem on a flat surface to check for straightness
See Fig. 10-7

Replace:
If Stem is bent.

Fig. 10-6
NOTE:
If light scratches or galling is present, repair the Stem by
sanding the surface with a 220 grit or finer sand paper. If
repair is not possible Kimray recommends replacement.

Repair:
If Stem surface shows light scratches.

NOTE: Fig. 10-7

Use putty knife to remove the Gasket from the flange
face. See Fig. 10-8

Cleaning: Flange
Use an air nozzle to clear any Face
particles on flange face.

Inspect the Removable Seat for excessive wear or

scratches. If the Seat is in good shape leave it in place.
Removing the Seat could result in additional damage.

Fig. 10-8

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
11 Lower Housing Assembly

Insert the first Back Up in the Lower Housing groove. The

Back Up will spiral into the groove. See Fig. 11-1

Using a narrow screw driver, insert the O-ring on top of

the Back Up.

Insert the second Back Up in the Lower Housing groove.

Use a brush to grease Back Ups and O-rings.

Before assembling, apply primer and Blue Loctite® to

short end of the Stem. Hand tighten the Stem into the
machined side of the Diaphragm Plate. See Fig. 11-2

To prevent shearing the O-ring, insert the Stem Guide on Stem

Stem with the radius side on top. See Fig. 11-3 Guide

Place the Lower Housing onto the Stem. Remove the

Stem Guide from the Stem. See Fig. 11-4

✴ ✴
O-ring Back Up

Fig. 11-3

Fig. 11-1

Fig. 11-2 Fig. 11-4

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY

Place the Seat Disc on the Stem. See Fig. 11-5

Insert the Seat into the Seat Disc.

Insert the Ratio Plug on top of the Seat.

Apply all purpose grease to threads of Stem and hand

start the Lock Nut threads. See Fig. 11-6

Hold the Seat Disc in one hand and use a socket to

tighten the Lock Nut. Stop when you start to feel the Seat
Disc turning in your hand. DO NOT OVER TIGHTEN, but Fig. 11-6
you do not want the Disc spinning on the Stem.
Use all
purpose ✴
Apply all purpose grease to the Lower Housing shoulder. grease Gasket
See Fig. 11-7 HERE

Place the Gasket on the Lower Housing shoulder.

Apply all purpose grease the top side of the Gasket.

Insert the Lower Housing into the Body. See Fig. 11-8
Make sure the breather hole aligns with the back side of
the flow arrow.
Fig. 11-7

Fig. 11-5 Fig. 11-8

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY

Upper
Communication
Fig. 11-9 shows the orientation of Lower Housing boss to Hole
Body.

Add all purpose oil to the Lower Housing until the oil is
above the lower communication hole and below the upper
communication hole. See Fig. 11-10, 11-11

Lower
Communication
Hole

Fig. 11-11

12 Diaphragm

Install Diaphragm onto Lower Housing assembly.

See Fig. 12-1

NOTE:
Be sure Diaphragm is placed in a ‘bowl’ position inside
the Lower Housing.

Fig. 11-9
✴
Diaphragm
Add Oil
Here

Fig. 11-10 Fig. 12-1

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
13 Upper Housing, Lower Seat

Place the Upper Housing on top of the Lower Housing.

Start all Bolts at least three rotations into Body and
run one Bolt down to the shoulder. Hand tighten the
remaining Bolts using the torque star pattern. Breather
Hole
See Fig. 13-1

Align the breather hole between outlet holes in Body.

See Fig. 13-2

Install Gasket and Lower Seat into the Upper Housing.

DO NOT OVER TIGHTEN. See Fig. 13-3

NOTE:
Make sure you tighten the Bolts in a criss-cross pattern to
avoid any miss alignment. For 2in., 3in., and 4in. tighten
bolts to 25-30 ft/lbs torque.

Fig. 13-2

✴ Seat
✴
Gasket

Fig. 13-1 Fig. 13-3

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
14 Filter

Apply primer and blue Loctite™ to both ends of Nipple

and thread one end into Filter and the other end into
pressure port of Diaphragm Housing. See Fig. 14-1

NOTE:
Clamp Filter Body into the vice using brass jaw
(not shown) and tighten.

Insert Screens (rough edge up) in the Filter.

See Fig. 14-2

Place O-ring onto the Filter Cap.

Filter Cap
✴
Hand start Filter Cap into Filter Body and tighten with a O-ring
wrench. See Fig. 14-2

✴
Filter Screens
6 Req'd.

Apply Primer and

blue Loctite™
Use brass jaws
to protect the
filter housing

Filter

Fig. 14-1

Fig. 14-2

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
15 Diaphragm Plate

Place the Pilot Diaphragm onto the Plate. Nut

See Fig. 15-1

Thread the Nut onto the Plate and tighten with pliers. Diaphragm ✴
See Fig. 15-2

Insert the Spring with the wider side on bottom.

See Fig. 15-3.

Insert the Pilot Diaphragm Assembly underneath the

Diaphragm Housing. See Fig. 15-4.

Fig. 15-2

Spring ✴
Nut
Diaphragm ✴

Diaphragm ✴

Plate

Fig. 15-3

Fig. 15-1

Fig. 15-4

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
Seat ✴

Diaphragm ✴

Insert the Pilot Plug with the larger ball diameter

contacting the Spring. See Fig. 15-5

NOTE:
Clean Pilot Seat if necessary.

Insert the Pilot Seat through the Diaphragm.

DO NOT shear the Diaphragm with the Pilot Seat threads.
See Fig. 15-6 Fig. 15-6

Install small end of Pilot Plug through Pilot Seat.

NOTE: ✴ Diaphragm Seat ✴

Plate or Pilot Seat edges may cut Diaphragm

Thread by hand to hand tight.

Using wrench or nut driver, tighten to 1/8 turn (15 in-lb)
See Fig. 15-7

Center Diaphragm and the Pilot Diaphragm into

counter-bore of Diaphragm Housing.

Tighten Pilot Seat with socket. DO NOT OVER TIGHTEN. Fig. 15-7

NOTE:
Diaphragm
Diaphragm Plate may cut the Diaphragm. Ring

Flip the Diaphragm Housing over and install Diaphragm

Ring. place on top of the Upper Housing. See Fig. 15-8

✴
Pilot Plug

Fig. 15-5 Fig. 15-8

✴ Recommended spare parts and stocked as repair kits

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
16 Spring, Bonnet

Apply all purpose grease on the top surface of the Plate

and place the Spring Plate on top. See Fig. 16-1

Place the Spring on top of the Spring Plate.

Install Spring Plate on top of Spring. Apply all purpose

grease to bevel of Spring Plate.

Install the Bonnet on top of the Spring Assembly.

See Fig. 16-2

Insert Bolts and tighten with a speed wrench.

NOTE:
Tighten Screws in a criss-cross pattern to avoid any miss
alignment. Tighten bolts to 25-30 ft/lbs torque.

Spring
Plate

Fig. 16-2
Apply All
Diaphragm Purpose
Ring Grease
HERE

Fig. 16-1

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY

17 Breather Plugs

NOTE:
Apply blue Loctite™ to Breather Plugs and hand start into
both Upper and Lower Housing bosses.

Insert Breather Plug in Upper Housing. See Fig. 17-1.

Insert Breather Plug in Lower Housing.

Insert Red Plug
The Breather Plug hole should stop in the five to eight HERE
o-clock position.

Install small Red Plug into the breather hole of the Lower
Housing Breather Plug. (Red Plug not shown) and re-
move after installation. See Fig. 17-2.

Fig. 17-2

Fig. 17-1

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PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY

18 Adjusting Screw, Tubing

NOTE:
Apply all purpose grease to the first few threads of the
Adjusting Screw.

Thread the Adjusting Screw with Nut, Washer and Pack-

ing Seal on top of the Bonnet. See Fig. 18-1

Connect the Tubing from the upstream communication

hole to the Filter. See Fig. 18-2

Upstream
Communication
Hole

Adjusting
Screw

Washer ✴

Packing ✴
Seal Fig. 18-2

Fig. 18-1

✴ Recommended spare parts and stocked as repair kits

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 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

ASSEMBLY
19 Gauge

Verify the needle is in the correct position.

NOTE:
Apply blue Loctite™ to the Gauge threads.

Thread the Gauge into the Filter and tighten with an

adjustable wrench. See Fig. 19-1

Apply
blue
Loctite™
Here

Fig. 19-1

www.kimray.com 29
PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

TESTING
20 Flow Direction, Adjusting Screw, Check For Leakage

Flow Direction
Make sure the air is flowing from upstream to
downstream. Regulators have an arrow showing the
direction of flow. See Fig. 20-1

Adjusting Screw
Use an adjustable wrench to run the Adjusting Screw all
the way down. See Fig. 20-1

Check for Leakage

Turn supply air off and make sure the Gauge is holding
pressure on the upstream side. If Gauge falls off then you
have leakage. See Fig. 20-2

Check if any leakage is coming out the downstream side.

Spray soaped water on Tubing, Housings, Breather Plugs

and Plugs. The identification of leakage will be noted if
any bubble shows up. See Fig. 20-2

Regulator Test
Once no leakage is detected, close upstream flow.

Fig. 20-1 Fig. 20-2

NOTE:
Make sure the regulator holds various levels of pressure.
(100 psi down to 5 psi by turning the Adjusting Screw out).

Troubleshooting
Problem Possible Cause(s) Possible Solution
Regulator appears to be stuck in Open position. Stopper has not been removed from breather Remove the stopper.
plug in lower housing. (BP Regulator)

Stem has seized Disassemble, clean, and re-kit valve

Regulator leaks through to downstream. Over tightened seat nut can cause seat to bulge DO NOT OVER TIGHTEN seat.
and leak.
Pilot vents gas continuously. Clean the pilot plug seat.
The pilot plug seat may be dirty.
Check 110 Diaphragm for rupture
Regulator will not open. A pilot seat may be loose. (BP Regulator) Tighten the pilot seat.

Stem has seized Disassemble, clean, and re-kit valve

30 www.kimray.com
 PRESSURE REGULATOR
Model: Pilot Operated
Installation, Operation & Maintenance Guide

Kimray is an ISO 9001- certified manufacturer.

Kimray quality assurance process maintains strict controls
of materials and the certification of parts used in Kimray pressure regulators.

Please visit our website for up to date product data www.Kimray.com

www.kimray.com 31
WHO WE ARE
Kimray is a manufacturer of oil and gas control equipment
based in Oklahoma City, Oklahoma, USA.

Trusted for generations, Kimray has been creating simple,

effective solutions for temperature, level, flow, and pressure
control since 1948. Common applications include separation,
heating, compression, dehydration, and artificial lift.

Buying from Kimray is about much more than the product. We

are partners with hearts to serve. The relationships between
our representatives and our customers extend from before the
sale through the life of the product. Our focus is not on short-
term profits but long-term growth for our customers.

Visit Kimray.com to learn more about our company and the

products we create.

Kimray.com

© 2015 Kimray Inc., RM:0003

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