Kimray GLYCOL PUMP Owner's manual

GLYCOL PUMP

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© 2018 Kimray Inc.

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Repair Guide
Contents
Introduction 4
DISASSEMBLY
Kimray Tools Used 6
Pressure Relief 7
Removing Suction and Discharge Blocks 7
Piston Discharge Piping 9
Legs 9
Main Piston Valve Housing 10
Control Valve Assembly Tubing 10
Pilot Piston Valve Housing 10
Cylinders 11
Pilot Piston Caps 13
Pilot Piston 13
Pilot Piston Valve Housing 13
Cleaning 14
Special Cases 14
INSPECTING PARTS
Piston Rod Assembly 15
Pistons 15
Cylinders 16
Piston Rod Seal Retainer 16
Pilot Piston 16
Check Valve Caps 17
Check Valve 17
Suction Block 17
Discharge Block 18
Main Piston Body 18
Suction and Discharge Seats 18
Pilot Piston Bearing 19
Piston Rod Gland 19
Pilot Piston Valve Housing Repair 20
ASSEMBLY
Pilot Piston Assembly 21
Cylinders Assembly 22
Pilot Piston Valve Housing 24
Discharge and Suction Block Assembly 27
Needle Valve Assembly 30

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GLYCOL PUMP
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Repair Guide
When a person needs to repair a Kimray glycol pump
and has never done so before, it can appear to be the
proverbial “can of worms” when it is disassembled and the
many parts and O-Rings are exposed. Even with a parts
drawing, it can be intimidating.
Nothing is as good as experience and hopefully, this
repair manual will help simplify the process. Years of
valuable experience was used to put together this manual
that details the disassembly, the examination of parts, and
the assembly of the Kimray Glycol Pump.
If these steps are followed, the pump should be “as good
as new” and ready for service. Also after going through
this manual, it will be easy to see why only replacing the
O-Rings will probably not give any acceptable length of
service.
There are typically four areas that can cause pump failure.
INTRODUCTION
I. GLYCOL CONTAMINATION
This can be caused by various things such as compressor
oils carrying over into the glycol that may cause O-Ring
swelling. Condensate (drip gas) can be another. If glycol
contamination is a constant and uncorrectable problem,
there are other elastomers available.
II. HEAT
The Kimray Glycol Pump comes standard from the factory
with Buna elastomers good for up to 200 degrees F.
Heat exchangers are essential in a dehydrator system
so that the dry glycol entering the pump is less than 200
degrees to prevent breaking down the elastomer. This
also enhances the dehydration process.
However, if there are continuing temperature related
failures, there are other materials available for elastomers
that will allow the pump to be used in higher temperatures.
III. FILTRATION
A “Y” strainer or other LOW PRESSURE filter is
recommended in the “dry” or “lean” suction line coming
from the surge (storage) tank to the pump. This will
catch any large particles that might cause the pump to
malfunction or damage it.
A HIGH PRESSURE filter is recommended in the “wet” or
“rich” glycol line coming from the bottom of the absorber
to the pump. There are several manufactures and types
of these filters.
This filter will catch smaller particles suspended in the
glycol such as salt and sand.
All filters need to be checked frequently and changed if
needed.
IV. IMPROPER REPAIR
Even with filtration, parts within the pump will wear over
time. Metal parts need to be examined very closely every
time a repair is done. Worn metal parts can cause lost
tolerances and therefore cause lost seals. Replacing
O-Rings ONLY , usually will not give long service. Piston
rod, pilot piston, cylinder, and piston surfaces are critical.
Anywhere there is an O-Ring surface should be checked
closely.
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!

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Repair Guide
DISASSEMBLY
KIMRAY TOOLS USED
SEAT REMOVAL TOOL
PART NUMBER PUMP SIZE
615 4020, 2020, 1720
614 9020, 5020, 21020,
10020, 45020, 20020
SEAL RETAINER TOOL
PART NUMBER PUMP SIZE
4456 4020, 2020, 1720
4457 9020, 5020
4458 21020, 10020
4459 45020, 20020
INSERT TOOLS FOR SUCTION SEAT
PART NUMBER PUMP SIZE
1542 4020, 2020, 1720
1543 9020, 5020
1544 21020, 10020
1545 45020, 20020

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Repair Guide
DISASSEMBLY
STEP 1
PRESSURE RELIEF
Loosen all plugs in inlet and outlet holes as there might
still be some trapped gas in the pump.
Slowly open needle valves for any additional trapped gas
(Fig. 1.1)
Figure 1.1
Figure 2.1
Figure 2.2
Figure 2.3
STEP 2
REMOVING SUCTION AND DISCHARGE BLOCKS
Remove Check Valve Caps from the Discharge Block of
the Main Piston Body (Fig. 2.1).
Remove Check Valve Caps from Suction Block of the
Main Piston Body.
NOTE: See special cases for further information (2).
Remove O-Ring from Check Valve Caps.
Use a pair of needle nose pliers to remove the Check
Valves from the Suction and Discharge Block (Fig. 2.2).
Remove upper and lower O-Rings from Check Valves.
NOTE: Check the darts in caps for excessive wear. DO
NOT waste time cleaning. (Ref. Fig 6.1 Inspection section).
Use a wrench and the seat pullers to remove the suction
seat (Fig. 2.3)
NOTE: Sometimes when condensate is present, the
O-Rings swell and the seats are hard to pull.
NOTE: See Special Cases for further information (1).

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Repair Guide
Remove O-Ring from Suction Seats.
Remove Discharge Block from the Main Piston Body (Fig.
2.4).
Use insert tool and hammer to remove Discharge Seats
(Fig. 2.5).
Remove O-Ring From Discharge Seat.
Remove Suction Block from Main Piston Body (Fig. 2.6).
Remove O-Rings from the back side of the Suction Block
Figure 2.4
Figure 2.5
Figure 2.6
DISASSEMBLY

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Repair Guide
Figure 3.1
Figure 3.2
STEP 3
PISTON DISCHARGE PIPING
Flip pump upside down and loosen the fitting from the
Pilot Piston Discharge Piping (Fig. 3.1).
Remove the Pilot Piston Discharge Piping fittings
(Fig. 3.2).
STEP 4
LEGS
Remove legs. Leave bolt assembly in the legs and set
aside (Fig. 4).
Figure 4.1

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Repair Guide
Figure 7.1
STEP 5
MAIN PISTON VALVE HOUSING
Remove the Main Piston Valve Housing by loosening the
bolts (Fig. 5.1).
Remove the O-Ring from the Main Piston Valve Housing.
Use the needle nose pliers to remove the “D” Slide
(Fig. 5.2).
Figure 5.1
Figure 5.2
Figure 6.1
DISASSEMBLY
STEP 6
CONTROL VALVE ASSEMBLY TUBING
Use two wrenches to loosen both ends of the tubing. Hold
the fitting elbow with one wrench and use the other one to
loosen the fitting cap (Fig. 6.1). This will prevent the fitting
from breaking (repeat on both ends of tubing).
NOTE: *See Special Cases for further information (3).
Replace legs and flip valve right side up.
STEP 7
PILOT PISTON VALVE HOUSING
Loosen the bolts on the Pilot Piston Valve Housing
(Fig. 7.1).
Remove Control Tubing.
Remove the O-Ring from the Pilot Piston Valve Housing.

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Repair Guide
DISASSEMBLY
STEP 8
CYLINDERS
NOTE: This procedure should be done in both sides of
the pump.
Before loosening the bolts, turn the tubing elbow to protect
the threads (Fig. 8.1).
Hold your hand over the block head to prevent oil splatter.
Loosen the bolts on the Cylinder Head.
Hold the Gland against the pump body and slide out the
Cylinder Head and remove the O-Ring (Fig. 8.2).
Remove the cylinder (Fig. 8.3).
Use a wrench to hold the Piston Rod in place and loosen
the lock nut from the other side of the piston (Fig. 8.4).
NOTE: If this is stuck, use a shop hammer to loosen.
Slide out the piston and then remove the O-Ring and two
backups.
Figure 8.1
Figure 8.2
Figure 8.3
Figure 8.4

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Repair Guide
DISASSEMBLY
Figure 8.7
Figure 8.8
Remove the O-Ring from the Piston Retainer Groove.
(Fig. 8.5)
Remove the O-Ring from the Piston Rod Gland (Fig. 8.6).
Remove the two O-Rings located in the communicating
hole grooves from the Pilot Piston Gland.
Repeat on both sides.
Remove the O-Ring and the Backup from the Piston Rod
Seal Retainer (Fig. 8.7).
Remove the Piston Rod Seal Retainer.
Repeat on both sides
Slide out the Piston Rod (Fig. 8.8).
Figure 8.5
Figure 8.6

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Repair Guide
STEP 9
PILOT PISTON CAPS
NOTE: This procedure should be done on both sides of
the pump.
Loosen the bolts and remove the Pilot Piston Caps (Fig.
9.1), then remove the Backups from the Pilot Piston Caps
Remove O-Ring from the Pilot Piston Caps.
DISASSEMBLY
Figure 9.1
Figure 11.1
Figure 10.1
STEP 10
PILOT PISTON
Tap the pilot piston with a rubber hammer until you slide it
out of the pump (Fig. 10.1).
Remove O-Ring and Backup from the Pilot Piston Bearing.
NOTE: If the Piston Bearing is tight use the Kimray Seal
Retainer tool to remove it.
Using the Kimray Seal Retainer Tool: Introduce the Seal
Retainer Tool into the Pilot Piston Hole and tap it with the
hammer. After removing the Pilot Piston Bearing, remove
its O-Ring and Backup.
STEP 11
PILOT PISTON VALVE HOUSING
Place Pilot Piston Valve Housing in a vice. Remove the
needle valve handles and stem lock with an
Allen wrench (Fig. 11.1).

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Repair Guide
DISASSEMBLY
Figure 12.1
STEP 12
CLEANING
Run it through parts washer. (2 minutes) If you can’t run
it through a parts washer, wipe down with shop towels.
(Fig. 12.1).
SPECIAL CASES
This section is provided to give assistance when you can
not tear down the pump with the normal procedures.
(1) PULLING SUCTION SEATS
Light the torch and adjust it.
Insert the torch in the seat hole lifting it in and out to
prevent damage to torch tip.
After seat in block is heated to glowing red or when you
hear the O-Ring pop, then turn torch off and submerge
suction block in water.
Insert seat pullers and tap upwards with wrench to remove
the seat.
NOTE: DO NOT REUSE THE SEATS AFTER HEATING
THEM WITH THE TORCH.
(2) DART CAPS
If the Dart Caps will not come apart, place the block on a
flat solid surface and strike Dart Caps forcefully several
times with a Shop Hammer.
NOTE: A useful surface is the flat anvil side of the vice.
Tighten Block in vice, then use any kind of wrench to
remove the Dart Caps from the Block.
NOTE: After hammering the Dart Caps they should come
loose. If they don’t, repeat procedure.
(3) FITTINGS
Sometimes the fittings will not come loose. If this happens,
use a shop hammer on bottom side of fitting as a backup
to keep it from bending.
Strike top side of fitting with a ball peen hammer several
times as this heats up the nut.
Loosen fitting with a wrench.

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Repair Guide
INSPECTING PARTS
Figure 13.1
Figure 13.2
Figure 14.1
MOST COMMONLY REPLACED PARTS
• Piston Rod
• Pistons
• Cylinders
• Gland Seal Retainers
• Pilot piston rod
• Check Valve Caps
• Darts
OCCASIONALLY CHANGED PARTS
• Suction Block
• Suction Seat
• Discharge Seat
• Discharge Block
• Glands
• Pilot Piston Retainers
STEP 13
PISTON ROD ASSEMBLY
Check for scoring. Replace if the scoring can be felt with
the finger nail (Fig. 13.1).
Repair if the rod has light scoring. They can sometimes be
smoothed out with 220 grit or fine emery cloth.
Check for uneven rod wear. Replace if an uneven surface
is felt (make sure to inspect the whole rod surface,
sometimes the wear is located on a small area) (Fig. 13.2).
STEP 14
PISTONS
Replace if the surface where the O-Ring seats shows
wear (Fig. 14.1).
NOTE: Check the outside surface where the O-Ring and
backup are placed. Check surface for an O-Ring groove.

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Repair Guide
STEP 15
CYLINDERS
Replace if there are ripples at each end of stroke area
(Fig. 15.1), or if there is scoring in the cylinder.
Note: A combination of cylinder wear and a piston wear
will decrease O-Ring squeeze.
INSPECTING PARTS
Figure 15.1
Figure 16.1
Figure 17.1
STEP 16
PISTON ROD SEAL RETAINER
These are very critical, since a lot of pump failures occur
from allowing wet and dry glycol to mix.
Replace if the surface where the O-Ring seats shows
wear (Fig 16.1).
NOTE: Check the inside surface where the O-Ring and
backup are placed. A good way to check this area is to
take a pencil and run it across the width of the surface and
see if there is any groove.
STEP 17
PILOT PISTON
Replace if there is a presence of scratches (Fig. 17.1), or
if there is a presence of uneven wear.
Repair if the rod has light scratches. They can sometimes
be smoothed out with 220 grit or fine emery cloth.

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Repair Guide
STEP 18
CHECK VALVE CAPS
Replace if clearance between the cap and Check Valve
is too much.
Note: Take a check valve and slide it into a cap. Check for
side to side play and make sure the check valve goes in
and out freely. A good way to check side to side play is to
check for play with new parts to be able to tell the
difference (Fig. 18.1)
Repair if there is interference between cap
and check valve (to clean Check Valve Cap, insert
appropriate size reamer), or if O-Ring gets stuck up in the
communicating hole.
NOTE: Make sure communicating hole is clear. That can
be done with an air nozzle or a small drill bit. (Fig. 18.2)
INSPECTING PARTS
Figure 18.1
Figure 18.2
Figure 19.1
Figure 20.1
STEP 19
CHECK VALVES
Replace if there is damage on the O-Ring ledge or stem
(Fig. 19.1).
NOTE: Inspect Check Valves for wear on stem and ledge
that holds the O-Ring. Sometimes when O-Ring comes off
the darts start hammering creating damage
to the ledge.
STEP 20
SUCTION BLOCK
Replace if O-Ring surface of wall has grooves or excessive
wear. (Fig. 20.1)
NOTE: When installing seats in to the block make sure
there is some resistance.

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Repair Guide
STEP 21
DISCHARGE BLOCK
Replace if seats are not flush with block surface
Note: Put seats in block. Take a straight edge and lay it
across the seats. They should be close to flush with the
block surface (Fig. 21.1). If seats sit low, this may cause a
leak between block and body.
INSPECTING PARTS
Figure 21.1
Figure 22.1
Figure 23.1
STEP 22
MAIN PISTON BODY
Replace if Main Piston Body has nicks or washouts around
communicating holes (Fig. 22.1)
Repair if there is wear in the body due
to seats impact. (Fig 22.2)
NOTE: After continuous hammering of Check Valves on
discharge seats, the seats can wear the body surface.
Figure 22.2
STEP 23
SUCTION AND DISCHARGE SEATS
Replace if there is excessive wear on seats (Fig. 23.1), or
if the segments of the Collet on Suction Seat are bent, or
if Check Valve doesn’t fit freely in seats.

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Repair Guide
INSPECTING PARTS
Figure 25.1
Figure 24.1
STEP 24
PILOT PISTON BEARING
Replace If there is a groove in the O-Ring surface
NOTE: Check inside wall for any groove (Fig. 24.1)
STEP 25
PISTON ROD GLAND
Replace if the surface where the Backup sits shows
inward wear. (Fig. 25.1)
Check this area for flatness, excessive washouts, or
communicating holes get damage.
Note: This surface gets damaged very easily and could
result in leaks between the Body and the Gland.

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Repair Guide
STEP 26
PILOT PISTON VALVE HOUSING REPAIR
If you are working on a newer pump, the Port plates will
be replaceable (Fig. 26.1). If you are working on an old
style pump, the surfaces on the Port plates will need to
be refinished (Fig. 26.2).
Use 80 grit sandpaper to buff out scratches or gouges.
Apply pressure with your hand in the top side by creating
a flat surface when sanding it. Move up and down 3 to 4
times.
To make sure the worst scratches have disappeared,
rotate the pilot piston housing 90º, press lightly and sand
it one more time (Fig 26.3). This will show if there are
more scratches to be sanded out.
After sanding it, use the air nozzle to make sure the
inside orifices are clear.
Repeat this process for the Main Piston Valve Housing.
Figure 26.1
Figure 26.2
Figure 26.3
INSPECTING PARTS

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Repair Guide
INSPECTING PARTS
STEP 27
PILOT PISTON ASSEMBLY
Insert the Pilot Piston Seal Retainer with the bevel side
facing inside the pump. Push them in until you feel a
mechanical stop (Fig. 27.1).
Reassemble the Pilot Piston Bearings using the two
O-Rings and three backups (Fig. 27.2). Be sure to use
a light gravity motor oil to generously lubricate all your
O-Rings and Backups when assembling.
Insert the Pilot Piston Bearing with its O-Ring and two
backups in to the Pilot Piston Body (Fig. 27.3).
Place in both sides the O-Ring and Backup in top of the
Pilot Piston Bearing.
Push the Pilot Piston Cap over bearings and seat the
O-Rings in place (Fig. 27.4).
Place the Pilot Piston Cap by bolting it to the body. (Fig.
27.5) Insert the Pilot Piston Rod in the other side of the
Pilot Piston Body (Fig. 27.6)
Place the other Pilot Piston Cap in the other side by bolting
it to the body. Use a screw driver to move the pilot piston
making sure it is loose.
If the pilot piston is stuck loosen bolts on the caps until you
release it, then retighten bolts and check again.
Figure 27.1
Figure 27.2
Figure 27.3
Figure 27.4