Kelso K2AV Instruction Manual

Installation, Operation, Inspection
and Maintenance Manual
ANGLE VALVE MODELS:
K2AV –Kelso 2” Angle Valve Series

1
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
Table of Contents
1.0
Introduction
2
1.1.
Precautions
2
1.2.
Regulations
2
1.3.
Technical Specifications
3
1.4.
Required Tools
4
2.0
Valve Installation
5
2.1
Preliminary Considerations
5
2.2
Installation Procedure
5
2.3
Leak Inspection
6
2.4
Valve Operation
6
3.0
Disassembly
7
3.1
Procedure
7
4.0
Inspection
13
4.1
Components
13
4.2
Cleaning
14
5.0
Assembly
15
5.1
Procedure
15
6.0
Pressure Testing and Final Assembly
20
6.1
Testing Procedure
20
6.2
Final Assembly
21
7.0
Maintenance
23
7.1
Testing Valves in Storage
23
7.2
Valve Repair
23
8.0
Special Guidelines
24
9.0
Warranty Information
24
10.0
Revisions
24

2
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
1.0 Introduction
Kelso Technologies is known for offering innovative products with
safety and reliability in mind. Our K2AV Angle Valve has been
designed and engineered to withstand the harsh commodities and
severe environmental conditions present in rail tank car service.
1.1 Precautions
The 2” Angle Valve can be used as a safety device in the storage and
transportation of a wide variety of fluids, many of which are hazardous and
could cause serious injury or damage. Only personnel which are properly
qualified should install, repair or rebuild the Angle Valve. Only certified
parts from Kelso or one of its authorized representatives should be used in
the Angle Valve. The Angle Valve may be installed on DOT tank cars that
carry hazardous chemicals and may travel under pressure.
Read these instructions prior to performing periodic maintenance or
repairs.
1.2 Regulations
Kelso valves are used in contact with a variety of products,
many of which are hazardous. The acceptance and
transportation of products are regulated by DOT and AAR in the
U.S.A and in Canada by CTC and Transport Canada.
Regulations of other governmental bodies must be complied
with. All personnel should be familiar with and follow these
regulations. Nothing in these instructions is intended to conflict
with or supersede these regulations.
NOTE: Specifications are subject to change without notice.

3
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
1.3 Technical Specifications
1.3.1 Figure 1.1 shows attributes of the K2AV Angle Valve. Figure 1.2
shows the General Arrangement of the valve and Figure 1.3 is a
general Bill of Materials for the given arrangement.
Valve Model
Orifice (In)
Weight (lbs.)
Flange
Thickness (In)
K2AV
2.125
30
0.75
Figure 1.1 K2AV Series Attributes
Figure 1.2 K2AV Series General Arrangement

4
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
ITEM NO.
QTY.
DESCRIPTION
1
1
BODY
2
1
STEM
3
1
PACKING SCREW
4
1
SEAL DISC
5
1
SEAT
6
1
SEAL RETAINER
7
1
K2AV HANDLE
8
1
KAV OPERATION DECAL
9
1
FACE PLATE
10
1
PACKING BOTTOM WASHER
11
1
FACE PLATE GASKET
12
1
2" NPT PLUG & CHAIN
13
1
JAM NUT
14
1
SHOULDER BOLT
15
1
WAVE SPRING
16
1
O-RING
17
1
JAM NUT
18
1
HEX NUT
19
1
PACKING KIT
20
6
SOCKET HEAD CAP SCREW
21
1
KAV NAMEPLATE (NOT SHOWN)
Figure 1.3 K2AV Series General Arrangement Bill of Materials
1.4 Required Tools and Torque Values
Required Tools
Sockets/Wrenches –½” and ¾”
Adjustable Wrench
Lint Free Cloth
Hook and Pick Tool
400 Grit Alum. Oxide Emery Cloth
Ratchet
Thread Locker
Torque Wrench
Anti-Seize
Wire Brush
Hey Key/Allen Wrench 3/8”
Torque Values
Item No.
Description
Torque Value
14
Seal Disc Bolt
8 ft.-lbs.
13
Seal Retainer Nut
20 ft.-lbs.
18
Handle Nut
30 ft.-lbs.
3
Packing Screw
25 ft.-lbs.
17
Packing Screw Jam Nut
40 ft.-lbs.
20
Face Plate Bolt
45 ft.-lbs.
12
Valve Plug
Wrench Tight

5
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
2.0 Valve Installation
Only companies and their personnel which are certified by the Association
of American Railroads shall perform maintenance and testing of Kelso
angle valves, pursuant to either M1002 or M1003.
2.1 Preliminary Considerations
New valves are tested, adjusted and sealed at Kelso. If a new valve has
been left in its original packaging, is undamaged and is not more than six
months old, it may be installed on a tank car without retesting or
recalibration. If the valve has exceeded six months, it must be returned
for retesting and recalibration. Prior to installation, ensure that the valve
remains clean and that the gasket sealing surfaces are not damaged in
any way, shape or form.
2.2 Installation Procedure
1. Prior to removing any valve or fitting from a tank, ensure
that the internal pressure is atmospheric and that
personnel exposure to hazardous chemicals are
eliminated.
2. When the securement bolts have been removed from the
mounting flange, remove the valve and discard the old
flange gasket.
3. The flange mating surface should be free from gouges,
scrapes, and excessive corrosion. With a tongue and
groove mating surface, ensure that while removing the
old gasket no damage is done to the bottom of the
groove. Any burrs, radial gouges and debris should be
removed.
4. A new valve should be kept in its original packaging to
prevent damage to the valve or its components.
5. A test certificate should be available to verify the test
date of the valve, if the last known test date was within
six months, the valve can be installed without retesting or
requalifying.
6. Place a new gasket on the tank mounting flange. Kelso
Technologies does not supply the flange gasket. Gasket
material should be compatible with the chemical being
shipped. Inspect the valve mating flange for defects as
described in Paragraph 3 above. Install the valve on the
mounting flange and secure using bolts, tightening to a
prescribed

6
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
7. Torque of 200 to 250 ft.-lbs. Our suggested value is only
to be used in the event your company does not have a
procedure for this.
8. Once the angle valve has been secured to the car, a
suitable leak test should be performed to ensure the
flange mating surfaces are pressure tight.
2.3 Leak Inspection
All newly installed valves must be tested under pressure to
confirm that no leaks are present.
WARNING: Loose nuts, improper tongue seating in the
flange, damaged and wrong size gaskets can result in leaks at
the valve mating surfaces.
2.4 Valve Operation
Operation of all valves must conform to all applicable TC,
AAR, DOT (Part 173.31, 174.67, etc.) and other
governmental bodies. Follow install facilities company
policies regarding valve operation.
1. A handle extension or “cheater” bar should not be used
to close valve. Excessive force will shear the angle
valve’s Teflon seat, making valve inoperable or difficult
to seal. Leaking valves that will not close by normal
means (closing using hand wheel) are defective and
should be removed from service.
2. Pipe plug threads should be clean, free from corrosion
and crossed and/or worn threads. The mating threads
of the valve body should also be in proper working
condition.
3. The angle valve contains an adjustable packing gland.
The Gland is factory set and under normal
circumstances a new valve needs no adjustment. To
prevent the packing screw jam nut from backing off,
torqueing it to 40 ft.-lbs. is required. Its primary function
is to prevent the packing screw from backing out while
the stem is turning.

7
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
3.0 Disassembly
Prior to any servicing of a Kelso Valve, ensure all participating
personnel have adequate personal protective equipment.
3.1 Procedure
1. Use an adjustable wrench to remove the valve plug from the face
plate of the angle valve. (Figures 3.1 & 3.2)
Figures 31. and 3.2 Valve Plug Removal
2. A 3/8” Allen/hex key wrench with ratchet/socket is needed to
remove the six bolts securing the face plate. Remove the face plate
and the face plate gasket. (Figures 3.3 & 3.4)
Figures 3.3. and 3.4 Face Plate Removal

8
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
3. Turn handle until the head of the seal disc bolt is visible. Loosen
and remove the seal disc bolt with a 5/32” hex key wrench. Turn
handle counterclockwise until the stem is free from the seal disc.
(Figures 3.5, 3.6 & 3.7)
Figures 3.5, 3.6 and 3.7 Seal Disc Removal
4. Remove seal disc from angle valve. Set aside.
(Figure 3.8)
Figure 3.8 Seal Disc Removed
Figure 3.7

9
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
5. With 3/4” wrench or socket remove handle nut and lift
the handle from the stem. (Figures 3.9 & 3.10)
Figures 3.9 and 3.10 Handle Removal
6. Loosen and remove the packing screw jam nut using
an adjustable wrench. (Figure 3.11)
Figure 3.11 Jam Nut Removal

10
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
7. Loosen and remove the packing screw using an
adjustable wrench. Remove O-ring from packing screw
using a hook and pick. (Figures 3.12, 3.13 & 3.14)
Figures 3.12, 3.13 and 3.14 Packing Screw / O-Ring Removal
8. Rotate the stem counter clockwise to remove the
stem from the angle valve body. (Figure 3.15)
Figure 3.15 Valve Stem Removal

11
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
9. Remove packing kit, packing base ring/bottom washer
and wave spring from stem. (Figures 3.16, 3.17 & 3.18)
Figures 3.16, 3.17 and 3.18 Stem Components Removal
10.To disassemble the seal disc, first remove the seal
retainer nut with a ½” wrench. (Figure 3.19)
Figure 3.19 Disassemble Seal Disc

12
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
11.Lift off seal retainer. (Figure 3.20)
Figure 3.20 Seal Retainer Removal
12.Remove seal from seal disc. Use a hook and pick as
needed. (Figures 3.21 & 3.22)
Figures 3.21 and 3.22 Seal Removal

13
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
4.0 Inspection
The valve and most components can be visually inspected without
removal from the tank car, however, a proper inspection should be
made whenever the valve is rebuilt or when suspect operation
warrants.
4.1 Components
1. Seal - The seal must be replaced when the valve is rebuilt.
Upon inspection the seal should be secured and concentric in
the sealing disc groove. For seals with etch, install with etch
facing up, toward (against) sealing disc. The etch identifies the
current seal pedigree compound and should be validated with
the car owner specifications. If the seal is installed with etch
down (away from) the sealing disc, it will not impact form, fit or
function but it may impact the integrity of the etch. Impact of
etch is not cause for condemnation. The seal should be free
from tears, folds, abrasions, cracking and a buildup of debris.
Replace when any of these defective conditions occur.
The seal has been manufactured with a proprietary
composition and should only be replaced with Kelso supplied
material.
It is recommended that any replacement parts be purchased
through Kelso Technologies for form, fit and function.
2. Seal Disc - The seal disc seat face and the seal retainer should
be smooth and free from scratches, nicks andgouges. The seat
face should also be free from paint, dirt, rust and scale prior to
the application of the seal.
3. Valve Seat - The valve seating area within the valve body must
be free from radial cuts, rust, and corrosion. The valve seat is
most crucial for correct valve operation and any discontinuity
can cause the valve to leak.
4. Stem - The stem once removed from the valve body should
have its threads examined. Some dings and wear are allowed
as long as the parallel wrenching surfaces at the top of the
screw remains square. If the surfaces become rounded, the
stem must be replaced. The threads of the stem should be
clean and lightly lubricated. An appropriate sized thread die
can be used to correct small imperfections and a flat file can be
used to correct slightly damaged ACME threads. If cracks
and/or fractures are discovered, replace the stem. The area

14
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
where the packing screw contacts the body must be free from
nicks, scratches and/or dings.
5. Body - Inspect body for corrosion degradation, particularly in the
seat area. Clean seat area from corrosion, contamination, pits,
etc., that may form leak paths. Tapped holes at side flange are
7/16-14. Discard body if threads are stripped, crossed or corroded.
6. Outlet Flange - The 2” NPT flange must be in good condition,
threads should not be stripped, crossed, etc. Threads can be
cleaned using a standard 2” NPT tap. A thread gage should be
used to ensure threads are not oversized. The standard hand-
tight engagement is 0.436” for 2” thread. The acceptable
tolerance is plus or minus one thread. If tolerance is exceeded
a new part must be obtained.
7. Packing Screw - The thread should be clean and sharp
without nicks, scratches, defects, etc. that will strip of gall the
threads when screwed into the body.
8. Plug –2” NPT plug must be in good condition, threads should
not be stripped, crossed, etc. Threads can be cleaned using a
standard 2” NPT die. A thread gage should be used to ensure
threads are not oversized. The standard hand-tight
engagement is 0.436” for 2” thread. The acceptable tolerance
is plus or minus one thread. If tolerance is exceeded a new
part must be obtained.
4.2 Cleaning
All components, excluding the Packing Kit and seal, of the
Kelso Angle Valve may be cleaned using the following:
1. Wire brushes and/or clean towel / cloth
2. Low pressure water, glass bead, sand or soda blasting
provided the blast media is not angular in form
3. A chemical / surfactant application, in conjunction with
manufactures prescribed instructions, to achieve a desired
result. It is suggested the chemical / surfactant be of neutral
pH to ensure the integrity of the metal composition
4. Regardless of cleaning method, it is suggested that the parts
be double rinsed and dried (w/ sanitary towel) prior to
reinstallation and immediately after any chemical / surfactant
application.
Disposal should be managed in accordance with all applicable
state and federal regulations.

15
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
5.0 Assembly
5.1 Procedure
1. Insert the seal in the seal disc and ensure that the seal is seated.
Install so that the flat portion of the seal is against the seal disc and
the bevel of the seal is away from the seal disc. (Figures 5.1 & 5.2)
Figures 5.1 and 5.2 Seal Area and Orientation
2. Install the seal retainer with the bevel facing away from the seal
disc. (Figures 5.3 & 5.4)
Figures 5.3 and 5.4 Seal Retainer and Orientation

16
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
3. Apply thread locker to retainer thread of seal disc and
install the seal retainer nut. Tighten and torque to 20 ft-
lb. (Figure 5.5)
Figure 5.5 Seal Retainer Installation
4. Place assembled seal disc into valve body. The seal faces down
and flat portion that accepts stem should face out through the face
of the body. (Figures 5.6 & 5.7)
Figures 5.6 and 5.7 Seal Disc in Valve Body

17
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
5. Apply lube to the outside diameter of the stem and the interior of
the packing kit. Then insert the wave spring, packing base
ring/bottom washer (flat side against wave spring) and packing kit
onto stem. The packing kit should interlock with the peaks fitting
into the groove, place on stem groove face first. Note: 6 spacers
are in the packing kit. Install on the square end of stem. (Figures
5.8 & 5.9)
Figures 5.8 and 5.9 Packing Kit onto Stem
6. Apply a thin coating of dry moly lube to the stem threads and thread
stem into valve body with square end of stem up, until the through
hole of the stem is centered in face of valve. (Figures 5.10 & 5.11)
Figures 5.10 and 5.11 Stem into Valve Body

18
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
7. Apply thread locker to seal disc bolt threads before
installation. Lift seal disc and install seal disc bolt.
Tighten to 8 ft-lbs. (Figure 5.12)
Figure 5.12 Seal Disc Installation
8. Insert O-ring into packing screw. (Figure 5.13)
Figure 5.13 O-Ring Installed into Packing Screw
9. Thread packing screw into body, square end up. Tighten
and torque to 25 ft-lbs. (Figure 5.14)
Figure 5.14 Packing Screw into Valve Body

19
K2AV SERIES ANGLE VALVE
© 2021 Kelso Technologies (USA) Inc. All Kelso Valves are Patent Protected. Detailed designs are subject to change without notice.
Kelso Technologies Inc. 1526 Texas Ave, Bonham, TX 75418, Phone: [phone]
Document No. –IOIM008
Revision 2 –6/1/2021 (Original Release 6/30/2016)
www.kelsotech.com
Printed in U.S.A.
10.Apply a thin layer of lube to packing screw jam nut. Then install
packing screw jam nut. While holding packing screw in place,
tighten jam nut. (Figure 5.15)
Figure 5.15 Packing Screw Installation
11.Align face plate gasket and face plate with holes on valve body.
Apply thread locker to bolt before installing onto valve body.
Tighten to 45 ft-lb. (Figures 5.16 & 5.17)
Figures 5.16 and 5.17 Face Plate Installation
NOTE: After assembly is complete, assure that the valve
plug is available, in order to proceed to testing.