50-01/650-01

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 INSTALLATION / OPERATION / MAINTENANCE

MODEL
100-01
Hytrol Valve
Description
The CIa-VaI Model 100-01 Hytrol Valve is a main valve for
CIa-VaI Automatic Control Valves. It is a hydraulically operated,
diaphragm-actuated, globe or angle pattern valve.

This valve consists of three major components; body, diaphragm

assembly, and cover. The diaphragm assembly is the only
moving part. The diaphragm assembly uses a diaphragm of nylon
fabric bonded with synthetic rubber. A synthetic rubber disc,
contained on three and one half sides by a disc retainer and disc
guide, forms a seal with the valve seat when pressure is applied
above the diaphragm. The diaphragm assembly forms a sealed
chamber in the upper portion of the valve, separating operating
pressure from line pressure.

Installation
1. Before valve is installed, pipe lines should be flushed of all installation with the cover UP is advisable. This makes internal
chips, scale and foreign matter. parts readily accessible for periodic inspection.
2. It is recommended that either gate or block valves be 6. Caution must be taken in the installation of this valve to insure
installed on both ends of the 100-01 Hytrol Valve to facilitate that galvanic and/or electrolytic action does not take place. The
isoIating the valve for preventive maintenance and repairs. proper use of dielectric fittings and gaskets are required in all
3. Place the valve in the line with flow through the valve in the systems using dissimilar metals.
direction indicated on the inlet nameplate. (See “Flow Direction” 7. If a pilot control system is installed on the 100-01 Hytrol Valve,
Section) use care to prevent damage. If it is necessary to remove fittings
4. Allow sufficient room around valve to make adjustments and or components, be sure they are kept clean and replaced
for disassembly. exactly as they were.
5. CIa-VaI 100-01 Hytrol Valves operate with maximum efficiency 8. After the valve is installed and the system is first pressurized,
when mounted in horizontal piping with the cover UP, however, vent air from the cover chamber and pilot system tubing by
other positions are acceptable. Due to size and weight of the loosening fittings at all high points.
cover and internal components of 8 inch and larger valves,

Principles of Operation Modulating

Restriction Control
Three Way Three Way
Pilot Control Pilot Control

Tight Closing Operation Full Open Operation Modulating Action

When pressure from the valve inlet (or When pressure in diaphragm chamber Valve modulates when diaphragm pres-
an equivalent independent operating is relieved to a zone of lower pressure sure is held at an intermediate point
pressure) is applied to the diaphragm (usually atmosphere) the line pressure between inlet and discharge pressure.
chamber the valve closes drip-tight. (5 psi Min.) at the valve inlet opens the With the use of a Cla-Val. "modulating
valve. control," which reacts to line pressure
changes, the pressure above the
diaphragm is varied, allowing the valve
to throttle and compensate for the
change.
Flow Direction Recommended Tools
The flow through the 100-01 Hytrol Valve can be in one of two 1. Three pressure gauges with ranges suitable to the instal-
directions. When flow is “up-and-over the seat,” it is in “normal” lation to be put at Hytrol inlet, outlet and cover connections.
flow and the valve will fail in the open position. When flow is “over-
the seat-and down,” it is in “reverse” flow and the valve will fail in 2. Cla-Val Model X101 Valve Position Indicator. This pro-
the closed position. There are no permanent flow arrow markings. vides visual indication of valve position without disassembly
The valve must be installed according to nameplate data. of valve.
BRIDGEWALL INDlCATOR
(cast into side of valve body)
3. Other items are: suitable hand tools such as screw-
Normal Flow Reverse Flow drivers, wrenches, etc. soft jawed (brass or aluminum) vise,
400 grit wet or dry sandpaper and water for cleaning.

Troubleshooting
The following troubleshooting information deals strictly with the All trouble shooting is possible without removing the valve from the
Model 100-01 Hytrol Valve. This assumes that all other compo- line or removing the cover. It is highly recommended to permanently
nents of the pilot control system have been checked out and are install a Model X101 Valve Position Indicator and three gauges in
in proper working condition. (See appropriate sections in unused Hytrol inlet, outlet and cover connections.
Technical Manual for complete valve).

SYMPTOM PROBABLE CAUSE REMEDY

Closed isolation valves in control system, or in main line. Open Isolation valves.
Fails to Close
Lack of cover chamber pressure. Check upstream pressure, pilot system, strainer, tubing, valves, or needle
valves for obstruction.

Diaphragm damaged. (See Diaphragm Check.) Replace diaphragm.

Diaphragm assembly inoperative. Clean and polish stem. Inspect and replace any damaged or badly eroded
Corrosion or excessive scale build up on valve stem. part.
(See Freedom of Movement Check)

Mechanical obstruction. Object lodged in valve. Remove obstruction.

(See Freedom of Movement Check)

Worn disc. (See Tight Sealing Check) Replace disc.

Badly scored seat. (See Tight Sealing Check) Replace seat.

Closed upstream and/or downstream isolation Open isolation valves.

Fails to Open valves in main line.

Insufficient line pressure. Check upstream pressure. (Minimum 5 psi flowing line pressure differential.)

Diaphragm assembly inoperative. Corrosion or excessive Clean and polish stem. Inspect and replace any
buildup on valve stem. (See Freedom of Movement Check) damaged or badly eroded part.

Diaphragm damaged. (For valves in "reverse flow" only) Replace diaphragm.

After checking out probable causes and remedies, the following three checks can be used to diagnose the nature of the
problem before maintenance is started. They must be done in the order shown.

Three Checks CAUTION:

The 100-01 Hytrol Valve has only one moving part (the diaphragm Care should be taken when doing the troubleshooting checks on
and disc assembly). So, there are only three major types of prob- the 100-01 Hytrol Valve. These checks do require the valve to
lems to be considered. open fully. This will either allow a high flow rate through the
valve, or the downstream pressure will quickly increase to the
First: Valve is stuck - that is, the diaphragm assembly is not free
to move through a full stroke either from open to close or vice inlet pressure. In some cases, this can be very harmful. Where
versa. this is the case, and there are no block valves in the system to
protect the downstream piping, it should be realized that the
Second: Valve is free to move and can’t close because of a worn valve cannot be serviced under pressure. Steps should be
out diaphragm. taken to remedy this situation before proceeding any further.
Third: Valve leaks even though it is free to move and the
diaphragm isn’t leaking.

2
 STEM TRAVEL
Diaphragm Check (#1 ) (Fully Open to Fully Closed)
Valve Size (inches) Travel (inches)
1. Shut off pressure to the Hytrol Valve by slowly closing upstream
Inches MM Inches MM
and downstream isolation valves. SEE CAUTION.
1 1/4 32 0.4 10
2. Disconnect or close all pilot control lines to the valve cover and 1 1/2 40 0.4 10
leave only one fitting in highest point of cover open to atmosphere. 2 50 0.6 15
3.With the cover vented to atmosphere, slowly open upstream 2 1/2 65 0.7 18
isolation valve to allow some pressure into the Hytrol Valve body. 3 80 0.8 20
Observe the open cover tapping for signs of continuous flow. It is 4 100 1.1 28
not necessary to fully open isolating valve. Volume in cover cham- 6 150 1.7 43
ber capacity chart will be displaced as valve moves to open posi- 8 200 2.3 58
tion. Allow sufficient time for diaphragm assembly to shift posi- 10 250 2.8 71
tions. If there is no continuous flow, you can be quite certain the 12 300 3.4 86
diaphragm is sound and the diaphragm assembly is tight. If the 14 350 4.0 100
fluid appears to flow continuously this is a good reason to believe 16 400 4.5 114
the diaphragm is either damaged or it is loose on the stem. In 24 600 6.5 165
either case, this is sufficient cause to remove the valve cover and 30 800 7.5 190
investigate the leakage. (See “Maintenance” Section for procedure.)
36 900 8.5 216

10. If the stroke is different than that shown in stem travel chart
this is a good reason to believe something is mechanically restrict-
ing the stroke of the valve at one end of its travel. If the flow does
COVER CHAMBER CAPACITY not stop through the valve when in the indicated “closed” position,
(Liquid Volume displaced when valve opens) the obstruction probably is between the disc and the seat. If the
flow does stop, then the obstruction is more likely in the cover. In
Valve size (inches) Displacement either case, the cover must be removed, and the obstruction locat-
Gallons Liters
ed and removed. The stem should also be checked for scale build-
1 1/4 .020 .07
up. (See “Maintenance, section for procedure.)
1 1/2 .020 .07
2 .032 .12 11. For valves 6” and smaller, the Hytrol Valve’s freedom of move-
2 1/2 .043 .16 ment check can also be done after all pressure is removed from
3 .080 .30 the valve. SEE CAUTION. After closing inlet and outlet isolation
4 .169 .64 valves and bleeding pressure from the valve, check that the cover
6 .531 2.0 chamber and the body are temporarily vented to atmosphere.
8 1.26 4.8 Insert fabricated tool into threaded hole in top of valve stem, and
10 2.51 9.5
lift the diaphragm assembly manually. Note any roughness. The
12 4.00 15.1
diaphragm assembly should move smoothly throughout entire
14 6.50 24.6
16 9.57 36.2
valve stroke. The tool is fabricated from rod that is threaded on
24 29.00 109.8 one end to fit valve stem and has a “T” bar handle of some kind
30 42.00 197.0 on the other end for easy gripping. (See chart in Step 4 of
36 90.00 340.0 “Disassembly” Section.)
12. Place marks on this diaphragm assembly lifting tool when the
valve is closed and when manually positioned open. The distance
Freedom of Movement Check (#2) between the two marks should be approximately the stem travel
4. Determining the Hytrol Valve’s freedom of movement can be shown in stem travel chart. If the stroke is different than that
done by one of two methods. shown, there is a good reason to believe something is mechani-
cally restricting the stroke of the valve. The cover must be
5. For most valves it can be done after completing Diaphragm
removed, and the obstruction located and removed. The stem
Check (Steps 1, 2, and 3). SEE CAUTION. At the end of step 3
should also be checked for scale build-up. (See “Maintenance”
the valve should be fully open.
Section for procedure.)
6. If the valve has a Cla-Val X101 Position Indicator, observe the
indicator to see that the valve opens wide. Mark the point of max- Tight Sealing Check (#3)
imum opening.
13. Test for seat leakage after completing checks #1 & #2 (Steps
7. Re-connect enough of the control system to permit the appli- 1 to 12). SEE CAUTION. Close the isolation valve downstream of
cation of inlet pressure to the cover. Open pilot system cock so the Hytrol Valve. Apply inlet pressure to the cover of the valve, wait
pressure flows from the inlet into the cover. until it closes. Install a pressure gauge between the two closed
8. While pressure is building up in the cover, the valve should valves using one of the two ports in the outlet side of the Hytrol.
close smoothly. There is a hesitation in every Hytrol Valve closure, Watch the pressure gauge. If the pressure begins to climb, then
which can be mistaken for a mechanical bind. The stem will either the downstream isolation valve is permitting pressure to
appear to stop moving very briefly before going to the closed posi- creep back, or the Hytrol is allowing pressure to go through it.
tion. This slight pause is caused by the diaphragm flexing at a Usually the pressure at the Hytrol inlet will be higher than on the
particular point in the valve’s travel and is not caused by a isolation valve discharge, so if the pressure goes up to the inlet
mechanical bind.
pressure, you can be sure the Hytrol is leaking. Install another
9. When closed, a mark should be made on the X101 Valve posi- gauge downstream of isolating valve. If the pressure between the
tion indicator corresponding to the “closed” position. The distance valves only goes up to the pressure on the isolation valve
between the two marks should be approximately the stem travel discharge, the Hytrol Valve is holding tight, and it was just the iso-
shown in chart. lation valve leaking.
3
Maintenance VALVE STEM THREAD SIZE
Valve Size Thread Size (UNF Internal)
Preventative Maintenance 1 1/4"—2 1/2" 10—32
3"—4" 1/4—28
The Cla-Val Co. Model 100-01 Hytrol Valve requires no lubrication or 6"—14" 3/8—24
packing and a minimum of maintenance. However, a periodic inspec- 16" 1/2—20
tion schedule should be established to determine how the operating 24" 3/4-16
conditions of the system are affecting the valve. The effect of these 30” 3/4-16
actions must be determined by inspection. 36” 3/4-16

Disassembly
Inspection or maintenance can be accomplished without removing 5. The next item to remove is the stem nut. Examine the stem
the valve from the line. Repair kits with new diaphragm and disc are threads above the nut for signs of mineral deposits or corrosion.
recommended to be on hand before work begins. If the threads are not clean, use a wire brush to remove as much
of the residue as possible. Attach a good fitting wrench to the nut
WARNING: Maintenance personnel can be injured and equipment and give it a sharp “rap” rather than a steady pull. Usually
damaged if disassembly is attempted with pressure in the valve. SEE several blows are sufficient to loosen the nut for further removal.
CAUTION. On the smaller valves, the entire diaphragm assembly can be held
by the stem in a vise equipped with soft brass jaws before
1. Close upstream and downstream isolation valves and independ- removing the stem nut.
ent operating pressure when used to shut off all pressure to the
valve. The use of a pipe wrench or a vise without soft brass jaws scars
the fine finish on the stem. No amount of careful dressing can
2. Loosen tube fittings in the pilot system to remove pressure from restore the stem to its original condition. Damage to the finish of
valve body and cover chamber. After pressure has been released the stem can cause the stem to bind in the bearings and the valve
from the valve, use care to remove the controls and tubing. Note and will not open or close.
sketch position of tubing and controls for re-assembly. The schemat-
ic in front of the Technical Manual can be used as a guide when 6. After the stem nut has been removed, the diaphragm assembly
reassembling pilot system. breaks down into its component parts. Removal of the disc from
the disc retainer can be a problem if the valve has been in serv-
3. Remove cover nuts and remove cover. If the valve has been in ice for a long time. Using two screwdrivers inserted along the out-
service for any length of time, chances are the cover will have to be side edge of the disc usually will accomplish its removal. Care
loosened by driving upward along the edge of the cover with a dull should be taken to preserve the spacer washers in water, partic-
cold chisel. ularly if no new ones are available for re-assembly.

7. The only part left in the valve body is the seat which ordinarily
does not require removal. Careful cleaning and polishing of inside
and outside surfaces with 400 wet/dry sandpaper will usually
restore the seat’s sharp edge. If, however, it is badly worn and
replacement is necessary, it can be easily removed.

Seats in valve sizes 1 1/4” through 6” are threaded into the valve
body. They can be removed with accessory X109 Seat Removing
Tool available from the factory. On 8” and larger valves, the seat
is held in place by flat head machine screws. Use a tight-fitting,
On 6” and smaller valves block and tackle or a power hoist can be
long shank screwdriver to prevent damage to seat screws. If upon
used to lift valve cover by inserting proper size eye bolt in place of
removal of the screws the seat cannot be lifted out, it will be nec-
the center cover plug. on 8” and larger valves there are 4 holes (5/8”
essary to use a piece of angle or channel iron with a hole drilled
— 11 size) where jacking screws and/or eye bolts may be inserted
in the center. Place it across the body so a long stud can be insert-
for lifting purposes. Pull cover straight up to keep from damaging
ed through the center hole in the seat and the hole in the angle
the integral seat bearing and stem.
iron. By tightening the nut a uniform upward force is exerted on
the seat for removal.
COVER CENTER PLUG SIZE
Valve Size Thread Size (NPT)
NOTE: Do not lift up on the end of the angle iron as this may force
1 1/4"—1 1/2" 1/4"
the integral bearing out of alignment, causing the stem to bind.
2"—3" 1/2"
4"—6" 3/4" ANGLE OR CHANNEL IRON
8"—10" 1"
NUT
12" 1 1/4"
14" 1 1/2"
16" 2"
24" 2" LONG STUD OR BOLT
30” & 36” 2” DO NOT
LIFT
4. Remove the diaphragm and disc assembly from the valve body.
With smaller valves this can be accomplished by hand by pulling
straight up on the stem so as not to damage the seat bearing. NUT OR BOLT HEAD
VALVE SEAT
On large valves, an eye bolt of proper size can be installed in the
stem and the diaphragm assembly can be then lifted with a block and
VALVE BODY
tackle or power hoist. Take care not to damage the stem or bearings.
The valve won't work if these are damaged.
4
Lime Deposits Inspection of Parts

One of the easiest ways to remove lime deposits from the valve After the valve has been disassembled, each part should be
stem or other metal parts is to dip them in a 5-percent muriatic examined carefully for signs of wear, corrosion, or any other
acid solution just long enough for the deposit to dissolve. This abnormal condition. Usually, it is a good idea to replace the rub-
will remove most of the common types of deposits. CAUTlON: ber parts (diaphragm and disc) unless they are free of signs of
USE EXTREME CARE WHEN HANDLING ACID. Rinse parts in wear. These are available in a repair kit. Any other parts which
water before handling. If the deposit is not removed by acid, then appear doubtful should be replaced. WHEN ORDERlNG
a fine grit (400) wet or dry sandpaper can be used with water. PARTS, BE SURE TO GIVE COMPLETE NAMEPLATE DATA,
ITEM NUMBER AND DESCRlPTlON.

NOTE: If a new disc isn’t available, the existing disc can be

turned over, exposing the unused surface for contact with the
seat. The disc should be replaced as soon as practical.

Reassembly

1. Reassembly is the reverse of the disassembly procedure. If a 3. Carefully install the diaphragm assembly by lowering the stem
new disc has been installed, it may require a different number of through the seat bearing. Take care not to damage the stem or
spacer washers to obtain the right amount of “grip” on the disc. bearing. Line up the diaphragm holes with the stud or bolt holes
When the diaphragm assembly has been tightened to a point on the body. on larger valves with studs, it may be necessary to
where the diaphragm cannot be twisted, the disc should be com- hold the diaphragm assembly up part way while putting the
diaphragm over the studs.
pressed very slightly by the disc guide. Excessive compression
should be avoided. Use just enough spacer washers to hold the
4. Put spring in place and replace cover. Make sure diaphragm
disc firmly without noticeable compression. is Iying smooth under the cover.
2. MAKE SURE THE STEM NUT IS VERY TIGHT. Attach a good
5. Tighten cover nuts firmly using a cross-over pattern until all
fitting wrench to the nut and give it a sharp “rap” rather than a
nuts are tight.
steady pull. Usually several blows are sufficient to tighten the
stem nut for final tightening. Failure to do so could allow the
6. Test Hytrol Valve before re-installing pilot valve system.
diaphragm to pull loose and tear when subjected to pressure.

Test Procedure After Valve Assembly

Due to the weight of the diaphragm assembly this procedure is
There are a few simple tests which can be made in the field to
not possible on valves 8” and larger. on these valves, the same
make sure the Hytrol Valve has been assembled properly. Do
determination can be made by carefully introducing a low
these before installing pilot system and returning valve to
pressure-less than five psi) into the valve body with the cover
service. These are similar to the three troubleshooting tests.
vented. SEE CAUTION. Looking in cover center hole see the
diaphragm assembly lift easily without hesitation, and then
1. Check the diaphragm assembly for freedom of movement
settle back easily when the pressure is removed.
after all pressure is removed from the valve. SEE CAUTlON.
Insert fabricated tool into threaded hole in top of valve stem, and
2. To check the valve for drip-tight closure, a line should be
lift the diaphragm assembly manually. Note any roughness,
connected from the inlet to the cover, and pressure applied at the
sticking or grabbing. The diaphragm assembly should move
inlet of the valve. If properly assembled, the valve should hold
smoothly throughout entire valve stroke. The tool is fabricated
tight with as low as ten PSI at the inlet. See “Tight Sealing
from rod that is threaded on one end to fit valve stem (See chart
Check” section.)
in Step 4 of “Disassembly” section.) and has a “T” Bar handle of
some kind on the other end for easy gripping.
3. With the line connected from the inlet to the cover, apply full
working pressure to the inlet. Check all around the cover for any
Place marks on this diaphragm assembly lifting tool when the
leaks. Re-tighten cover nuts if necessary to stop leaks past the
valve is closed and when manually positioned open. The dis-
diaphragm.
tance between the two marks should be approximately the stem
travel shown in stem travel chart. (See “Freedom of Movement
4. Remove pressure, then re-install the pilot system and tubing
Check” section.) If the stroke is different than that shown, there
exactly as it was prior to removal. Bleed air from all high
is a good reason to believe something is mechanically restricting
points.
the stroke of the valve. The cover must be removed, the obstruc-
tion located and removed. (See “Maintenance” Section for
5. Follow steps under “Start-Up and Adjustment” Section in
procedure.)
Technical Manual for returning complete valve back to service.

5
 1 6
25 17
5 7
2
24 8 9
10

INLET OUTLET
3

4
TOP VIEW
14 16
GLOBE PATTERN
PARTS LIST
Item Description
1. Pipe Plug
2. Drive Screws (for nameplate)
3. Hex Nut (8” and larger)
4. Stud (8” and larger) 26
5. Cover Bearing 27
6. Cover 9
7. Stem Nut
8. Diaphragm Washer
9. Diaphragm
10. Spacer Washers
11. Disc Guide 12
12. Disc Retainer
13. Disc
14. Stem 15
15. Seat OUTLET
14
16. Body
17. Spring
22. Flat Head Screws (8” and larger)
23. Seat O-Ring
24. Hex head Bolt (1 1/4” thru 4”) 16
25. Nameplate
26. Upper Spring Washer (Epoxy coated valves only)
27. Lower Spring Washer (Epoxy coated valves only) INLET
28. Cover Bearing Housing (16” only) ANGLE PATTERN
29. Cover O-Ring (16’” only)
30. Hex Bolt (16” only)
31. Pipe Cap (16” only)
31
13

12 28
13 22
10
11
30
15 14
23

14

23

5 29

1 1/4" - 6" SEAT DETAIL 8" - 24" SEAT DETAIL 16" COVER DETAIL

6
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
100-01
Hytrol Valve Service Data
Description 100-01 Hytrol Valve Description 100-20 600 Series Hytrol Valve
The CIa-VaI Model 100-01 Hytrol Valve is a main valve for The CIa-VaI Model 100-20 Hytrol Valve (600 Series main valve)
CIa-VaI Automatic Control Valves. It is a hydraulically operated, have only one part -the body- that is different from standard 100
diaphragm-actuated, globe or angle pattern valve. Series Cla-Val main valve parts. The remaining parts of the 600
series main valve are standard Cla-Val main valve parts.
This valve consists of three major components; body, diaphragm All service and maintenance information for the standard 100
assembly, and cover. The diaphragm assembly is the only Series main valves also apply to the 600 series main valves.
moving part. The diaphragm assembly uses a diaphragm of nylon The most important thing to remember when ordering main
fabric bonded with synthetic rubber. A synthetic rubber disc, valve repair kits and replacement parts, except for the body, all
contained on three and one half sides by a disc retainer and disc other parts are going to be for a smaller size main valve. Cla-
guide, forms a seal with the valve seat when pressure is applied Val identifies main valve parts with the flange size of the stan-
above the diaphragm. The diaphragm assembly forms a sealed dard 100 Series main valve. Refer to the "Main Valve Sizes”
chamber in the upper portion of the valve, separating operating chart below.
pressure from line pressure.

HYTROL Service Data

Stem Cover Capacity Cover Cover Nut or Bolt Cover Cover Plug Cover Torque Stem Nut** Stem Nut Torque
HYTROL SIZE Valve Stem
Travel Displacement Center Lifting (ft. Lbs.)
100-01 100-20 Thread Thread Socket
Plug Socket Qty Holes Thread Socket ft. Lbs. in. Lbs. Thread
UNF-Internal (Bolt) (Long)
NPT UNC
inches mm inches mm inches mm Gallons Liters Lubed DRY
1" 25 0.3 8 1/4" 1/4" - 20 (B) 7/16" 8 4 48 3/8" - 24 4 6
1 1/4" 32 0.4 10 0.020 0.07 10 - 32 1/4" 5/16" - 18 (B) 1/2" 8 8 96 7/16" -20 6 10
1 1/2" 40 0.4 10 0.020 0.07 10 - 32 1/4" 5/16" - 18 (B) 1/2" 8 8 96 7/16" -20 6 10
2" 50 0.6 15 0.032 0.12 10 - 32 1/2" 3/8" - 16 (B) 9/16" 8 3/8" 7/16" 12 1/2" - 20 3/4" 10 15
2 1/2" 65 0.7 18 0.043 0.16 10 - 32 1/2" 7/16" - 14 (B) 5/8" 8 1/2" 9/16" 20 5/8" - 18 15/16" 21 30
3" 80 4" 100 0.8 20 0.080 0.30 1/4 - 28 1/2" 1/2" - 13 (B) 3/4" 8 1/2" 9/16" 30 5/8" - 18 15/16" 21 30
4" 100 6" 150 1.1 23 0.169 0.64 1/4 - 28 3/4" 3/4" - 10 (B) 1 1/8" 8 3/4" 5/8" 110 3/4" - 16 1 1/16" 40 60
6" 150 8" 200 1.7 43 0.531 2.00 3/8 - 24 3/4" 3/4" - 10 (B) 1 1/8" 12 3/4" 5/8" 110 7/8" - 14 1 5/16" 85 125
8" 200 10" 250 2.3 58 1.26 4.80 3/8 - 24 1" 3/4" - 10 1 1/4" 16 5/8" - 11 1" 13/16" 110 1 1/8" -12 1 13/16" 125 185
10" 250 12" 300 2.8 71 2.51 9.50 3/8 - 24 1" 7/8" - 9 1 7/16" 20 3/4" - 10 1" 13/16" 160 1 1/2" -12 1 7/8" 252 375
12" 300 16" 400 3.4 86 4.0 15.10 3/8 - 24 1 1/4" 1 1/8" - 7 1 13/16" 20 3/4" - 10 1" 13/16" 390 1 1/2" -12 2 1/2" 270 400
14" 350 3.9 99 6.5 24.60 3/8 - 24 1 1/2" 1 1/4" - 7 2" 20 1" - 8 1" 13/16" 545 1 1/2" -12 2 1/2" 280 420
16" 400 20", 24" 600 4.5 114 9.6 36.20 1/2 - 20 2" 1 1/4" - 7 2" 20 1" - 8 1" 13/16" 545 2" - 16 3" 500 750
20" 500 5.63 143 12 45.40 3/4 - 16 1 1/2" 1 3/8" - 6 2 1/16" 24 1" - 8 1" 13/16" 670 2 1/4" - 16 3 1/2" 930 N/R
24" 600 30" 800 6.75 165 29.0 108.80 3/4 - 16* 3/4" 1 1/2" - 12 2 3/8" 24 1 1/8"- 7 1" 13/16" 800 3" - 12 Special 1350 N/R
* Adapter p/h Grade 5 Bolts
** Must Use ONLY
2594101E "Heavy" Grad Nuts
Cla-Val Supplied part
inside 1/4" - 28" Tighten cover nuts in a "star" cross-over pattern
 BOLT/NUT TORQUING PROCEDURES ON VALVE COVERS 100-01 Hytrol Main Valve Assembly
PIPE PLUG
COVER HEX NUT
1 3 1 6 8" and Larger
1 3
PIPE PLUG
8 3
Cover Bolt
4 5
6 6
8 6" and Smaller
COVER BEARING
BOLTS BOLTS BOLTS SPRING
4 7
STEM NUT
4 2
4 2 5 2 DIAPHRAGM WASHER
1 5 1 9 1 15 *DIAPHRAGM
16 5 17 9
12 7 20 7
8 13
5 13
0 3 12 3 DISC RETAINER
12 3
12 16 20
BOLTS 4 BOLTS 11 4 BOLTS 11 *SPACER WASHERS
4 9
14 6 KO Anti-Cavitation *DISC
14 7 Trim Option
8 11 8 19
6 15 10 16 DISC GUIDE
6 2 10 2 2 18 KO
DISC GUIDE
Follow this procedure when reassembling MAIN Valve: STEM
1. Tightens bolts/nuts in a “Star” or “Cross-Over” pattern following the KO Seat Screw
SEAT 8" and Larger
SEAT
numbers shown above to insure that cover seats evenly on the diaphragm
material and body.
SEAT O-RING
2. Torque the bolt/nuts in three stages with a "Star" or "Cross-Over" pattern STUD
for each stage: 8" and Larger
A. To approximately 10% of final torque.
BODY
B. To approximately 75% of final torque. PIPE PLUG
C. To final required torque. (Globe or Angle)
3. Valves that are to be tested to 375 PSI or higher should be retorqued *Repair Parts
after 24 hours.
CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
© Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. N-100-01 (R-7/08)
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
100-20(Reduced Internal Port)

600 Series Hytrol Valve

SERVICE AND MAINTENANCE OF 600 SERIES
The 100-20 Hytrol valve has all of the basic features and advan-
VALVES
tages of the original 100-01 Hytrol. Only one part has been
changed - the body. It is designed with different size inlet, seat
The 600 series main valves have only one part -the body- that is
and outlet openings. The 100-20 Hytrol has inlet and outlet
different from standard 100 Series Cla-Val main valve parts. The
flanges one valve size larger than the seat opening size. This
remaining parts of the 600 series main valve are standard Cla-
results in what is sometimes called a ''reduced port' main valve.
Val main valve parts. All service and maintenance information
For example, a 4" 100-20 valve has a 3" seat. Note: valve size
for the standard 100 Series main valves in this manual also
is always determined by the flange size. The following chart
apply to the 600 series main valves.
compares the 100-01 and the 100-20 main valves.
The most important thing to remember when ordering main valve
Basic Main Valve Size Comparison
repair kits and replacement parts, except for the body, all other
parts are going to be for a smaller size main valve. Cla-Val iden- Globe Pattern Valves
tifies main valve parts with the flange size of the standard 100 Seat Size
Flange Size (inch)
Series main valve. Refer to the "Main Valve Sizes Comparison" 100-01 (100 Series) 100-20 (600 Series)
chart. For example, if you are servicing a 6" 100-20 Hytrol and 3 3 2
needed a repair kit, you would order a repair kit for a 4" 100-01 4 4 3
Hytrol. This kit is also suitable for a 6" 100-20 Hytrol. Complete 6 6 4
Technical Manuals include a repair kit data sheet N-RK that 8 8 6
shows this relationship. 10 10 8
12 12 10
When you order repair parts, it is a good idea to include valve
14 14 ----
nameplate data (size, catalog number, and part number) and
description of the parts desired. Do this to be sure parts will fit 16 16 12
the valve you are working on and not be too big for it. Pilot con- 18 ---- 16
trols and repair kits maintenance information remain the same 20 20 16
for 100 or 600 Series valves. 24 24 16
30 30 24
36 36 30
UNDERSTANDING THE 600 SERIES VALVES 42 ---- 36
48 ---- 36
In 1987, Cla-Val introduced the Model 100-20 Hytrol as the basic
Angle Pattern Valves
main valve for the 600 Series of automatic control valves. To
identify all new valves using the 100-20 Hytrol, an existing cata- Seat Size
Flange Size (inch)
log number is modified. Making a 600 Series catalog number is 100-01 (100 Series) 100-20 (600 Series)
simply done by using a "6" in front of the two digit catalog num- 4 4 3
bers or replacing the "2" with a "6" in three digit catalog num- 6 6 4
bers. Current schematics reflect both catalog numbers together 8 8 6
separated by a slash ( i.e. - 90-01/690-01, 58-02/658-02, 210-
01/610-01, etc). Since these two valves 'share' the same catalog The 100-20 Hytrol is available only in ductile iron, 150 and 300
number and schematic, they provide the same function in a sys- pressure class, and Bronze trim standard. Available extra cost
tem. The only difference between the two valves is the relative main valve options include stainless steel trim, epoxy coating,
capacity of the two main valve series. Dura-Kleen stem, Delrin sleeved stem, and high temperature rub-
ber parts. All four basic main valves have a 600 Series version
The 100-01 Hytrol is the basic main valve for Cla-Val automatic available with all of the same benefits and size relationships.
control valves. This valve is the current version of the Clayton The following chart shows the relationship of Cla-Val main valve
Hytrol valve design originated in 1936. The 100-01 Hytrol is catalog numbers.
designed as a full flow area valve. This means that the inlet,
seat and outlet openings are the same size. Thus, the pressure
Cla-Val Main Valves
drop is kept to a minimum for this globe style design. Catalog Number
Catalog Name Circa 1936 100-Series 600 Series
Hytrol 100 (Angle =2100) 100-01 100-20
Powertrol 100P & 100PA 100-02 100-21
Powercheck 100PC & 100PCA 100-03 100-22
Hycheck 181 100-04 100-23
100-20 PARTS LIST
NO. DESCRIPTION

1 Pipe Plug
2 2 Drive Screws (for nameplate)
3 Hex Nut (8" and larger)
4 Stud (8" and larger)
5 Cover Bearing
25
6 Cover
7 Stem Nut
8 Diaphragm Washer
9 Diaphragm
1 24 3 4 10 Spacer Washers
11 Disc Guide
12 Disc Retainer
13 Disc
TOP VIEW 14 Stem
15 Seat
16 Body
6 17 Spring
9
22 Flat Head Screws (10" and larger)
8
23 Seat O-Ring
24 Hex Bolt (3 " Thru 6")
12 25 Nameplate (Mounted on inlet flange)
13 26 Upper Spring Washer (Epoxy coated valves only)
15 27 Lower Spring Washer (Epoxy coated valves only)
GLOBE
OUTLET 28 Cover Bearing Housing (20" & 24" & 30")
INLET
29 Cover Bearing Housing O-Ring (20"& 24" & 30")
30 Hex Bolt (20" & 24")
31 Pipe Cap (20" & 24 & 30"")
11

14
ANGLE WHEN ORDERING PARTS, BE SURE TO GIVE COMPLETE
INLET 16 NAMEPLATE DATA, ITEM NUMBER AND DESCRIPTION.

31
14 14
10
13
26 28
5 15
17
27 22
7 30
8
9 29

5
12 23
11
3" — 6" COVER DETAIL 10" — 24" SEAT DETAIL 20" — 24" COVER DETAIL

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice.
N-100-20 (R-5/08)
 PARTS LIST

X42N-2
Strainer and Needle Valve Assembly
33 When ordering parts,
8
11
please specify:
12
• All nameplate data
3/8 NPT • Item Number
3 4 • Description

58
1
Size Stock Number
4
3/8" x 3/8" 68372C
2

5
1
2 MAX.
8
3

Inlet Outlet

10

9
1
2 MAX.
4
7

ITEM DESCRIPTION MATERIAL PART NO.

1 Jam Nut —Hex Sil Brz 6779806G
2 Bonnet S.S. 67910A
3 "O" Ring—Bonnet Syn Rub 00713J
4 Stem S.S. 67907G
5 "O" Ring—Stem Syn Rub 00708J
6 Plug—Pipe 1/4 Bre. 6784702A
7 Strainer Plug 303 67911J
8 "O" Ring—Plug NBR 00751J
9 Screen Monel 68373A
10 Body Rd Brs 67905A
11 Plug—Pipe 1/8 Brass 6784701C
12 Plug—Pipe 3/8 Brass 67660-03F

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. PL- X42N-2 (R-11/08)
This page was intentionally left blank!
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
CRL
Pressure Relief Control
DESCRIPTION INSPECTION
The CRL Pressure Relief Control is a direct acting, spring loaded, Inspect all parts for damage, or evidence of cross threading. Check
diaphragm type relief valve. It may be used as a self-contained valve or diaphragm and disc retainer assembly for tears, abrasions or other dam-
as a pilot control for a Cla-Val Main valve. It opens and closes within age. Check all metal parts for damage, corrosion or excessive wear.
very close pressure limits. REPAIR AND REPLACEMENT
INSTALLATION Minor nicks and scratches may be polished out using 400 grit wet or dry
sandpaper fine emery or crocus cloth. Replace all O-rings and any dam-
The CRL Pressure Relief Control may be installed in any position. The
aged parts.
control body (7) has one inlet and one outlet port with a side pipe plug
When ordering replacement parts, be sure to specify parts list item num-
(24) at each port. These plugs are used for control connections or gauge
ber and all nameplate data.
applications. The inlet in the power unit body (6) is the sensing line port.
A flow arrow is marked on the body casting. REASSEMBLY
OPERATION In general, reassembly is the reverse of disassembly. However, the fol-
lowing steps should be observed:
The CRL Pressure Relief Control is normally held closed by the force of
the compression spring above the diaphragm; control pressure is applied 1. Lubricate the O-Ring (18) with a small amount of a good grade of
under the diaphragm. waterproof grease, (Dow Corning 44 medium grade or equal).
Use grease sparingly and install O-ring in powerunit body (6).
When the controlling pressure exceeds the spring setting, the disc is lifted
off its seat, permitting flow through the control. 2. Install stem (19) in powerunit body (6). Use a rotating motion with
minimum pressure to let stem pass through O-ring.
When controlling pressure drops below spring setting, the spring returns
the control to its normally closed position. Do Not Cut O-Ring.

ADJUSTMENT PROCEDURE 3. Install O-ring (5) at top of stem (19). Place lower diaphragm
washer (17) on the stem with the serrated side up. Position
The CRL Pressure Relief Control can be adjusted to provide a relief set-
diaphragm (16), upper diaphragm washer (15), with serration down,
ting at any point within the range found on the nameplate.
and belleville washer (14) with concave side down.
Pressure adjustment is made by turning the adjustment screw (9) to vary
4. Position powerunit body (6) as shown on parts list drawing (top view).
the spring pressure on the diaphragm. Turning the adjustment screw
clockwise increases the pressure required to open the valve. 5. Continue reassembly as outlined in disassembly steps 1 through 3.
Counterclockwise decreases the pressure required to open the valve.
When pressure adjustments are complete the jam nut (10) should be
tightened and the protective cap (1) replaced. If there is a problem of
tampering, lock wire holes have been provided in cap and cover. Wire Note: Item (4) Screw will have a quantity of 8 for the 0-75 and 20-200psi
the cap to cover and secure with lead seal. design and a quantity of 4 for the 100-300psi design. Item (25) Screw is
DISASSEMBLY used on the 100-300psi design only. Install item (25), before item (4) for
The CRL Pressure Relief Control does not need to be removed from the preload of item (12) spring.
line for disassembly. Make sure that pressure shut down is accompanied
prior to disassembly. If the CRL is removed from the line for disassembly
be sure to use a soft jawed vise to hold body during work.
Refer to Parts List Drawing for Item Numbers.
1. Remove cap (1), loosen jam nut (10) and turn adjusting SYMPTOM PROBABLE CAUSE REMEDY
screw counterclockwise until spring tension is relieved.
2. Remove the eight screws (4) holding the cover (3) and Fails to open. Controlling pressure Back off adjusting
powerunit body (6). Hold the cover and powerunit together too low. screw until valve
and place on a suitable work surface. opens.
See NOTE under REASSEMBLY. Fails to open with Mechanical obstruc- Disassemble,
3. Remove the cover (3) from powerunit body (6). The spring spring compression tion, corrosion, scale locate,and remove
(12) and two spring guides (11). removed. build-up on stem. obstruction, scale.
4. Remove nut (13) from stem (19) and slide off the belleville washer Leakage from cover Diaphragm Damage Disassembly replace
(14), the upper diaphragm washer (15) and the diaphragm (16). vent hole when con- damaged
5. Pull the stem (19) with the disc retainer assembly (21) through the trolling pressure is diaphragm.
bottom of powerunit. The lower diaphragm washer (17) will slide off applied.
of stem top.
6. Remove jam nut (23) and disc retainer assembly (21) from stem. Loose diaphragm Tighten upper
Use soft jawed pliers or vise to hold stem. The polished surface of assembly. diaphragm washer.
stem must not be scored or scratched. Fails to close. No spring compres- Re-set pressure
7. The seat (22) need not be removed unless it is damaged. If removal sion. adjustment.
is necessary use proper size socket wrench and turn counterclock-
wise. Fails to close with Mechanical obstruc- Disassemble, locate
Note: Some models have an integral seat in the body (7). spring compressed. tion. and remove
obstruction.

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. N-CRL (R-1/08)
This page was intentionally left blank!
 PARTS LIST

CRL
1/2" & 3/4" PRESSURE RELIEF CONTROL
Body with
TRUE LOCATION OF
SENSING integral Seat PART
CONNECTION SIZE SPRING
(TYP.)
45º NUMBER
3.12 1/2” 0-75 PSI 79222-01E
DIA.

1/2” 20-105 PSI 79222-05F

4 ADJUSTING SCREW 1/2” 20-200 PSI 79222-02C
(1/2" 20UNF THREAD)
24
1/2” 100-300 PSI 82809-01D
1 1A 3/4” 0-75 PSI 79229-01K
9
3/4” 20-105 PSI 79229-03F
10
Ajusting Screw
9
(3/8" - 16UNF THREAD)
10
10.44
MAX.
3 3/4” 20-200 PSI 79229-02H
3
11
12
3/4” 100-300 PSI 86005-01E
11
7.44

13 11
12 MAX For 250-600 PSI Contact Factory
14
15 11
APPROX. INCREASE
1/8 - 27 NPT 4 CRL FOR EACH
SENSING
CONNECTION 16 Range PSI CLOCKWISE TURN OF
(TYP.) ADJUSTING SCREW
17 2
18
5 0 to 75 8.5 PSI
19
2 20 to 105 12.5 PSI
21 7
6
INLET OUTLET 20 to 200 28.0 PSI
20
.71 100 to 300 18.0 PSI
.71

8 22 23 7 0 TO 75 AND When ordering parts please specify:

20 TO 200 PSI 1. All Nameplate Data
DESIGN 100 To 300 psi Design
2. Item Part Number
3. Item Description

Item Description Material Part Number Part Number Part Number Part Number
0-75 20-105 20-200 100-300
1 Cap Plastic 67628J 67628J 67628J 1257601D
1A Cap 100-300 psi Design Plastic 1257601D 1257601D 1257601D 1257601D
2 Nameplate Brass -- -- -- --
3 Cover Bronze C2544K C2544K C2544K C2544K
4* Screw Fil. Hd. 10-32 x 1.88 (Qty 8) 303 SS 6757867E 6757867E 6757867E 6757867E
5* O-Ring Rubber 00902H 00902H 00902H 00902H
6 Body, Powerunit Bronze 7920504D 7920504D 7920504D 7920504D
7 1/2” Body Bronze C7928K C7928K C7928K C7928K
3/4” Body Bronze C9083B C9083B C9083B C9083B
8* O-Ring, Seat Rubber 00718H 00718H 00718H 00718H
9 Screw, Adjusting Brass 7188201D 7188201D 7188201D 82811B
10 Nut Hex (Locking) 303 SS 6780106J 6780106J 6780106J 6780606H
11 Guide, Spring 303 SS 71881H 71881H 71881H 1630301J
12 Spring CHR/VAN 71884B 20632101E 71885J 1630201A
13 Nut, Stem Upper Bronze 73034B 73034B 73034B 73034B
14 Washer, Belleville Steel 7055007E 7055007E 7055007E 7055007E
15 Washer, Diaphragm (upper) 303 SS 71891G 71891G 71891G 71891G
16* Diaphragm Rubber C1505B C1505B C1505B C1505B
17 Washer, Diaphragm (lower) 303 SS 45871B 45871B 45871B 45871B
18* O-Ring, Stem Rubber 00746J 00746J 00746J 00746J
19 Stem 303 SS 8982041F 8982041F 8982041F 8982041F
20* O-Ring, Body Rubber 00767E 00767E 00767E 00767E
21* Retainer Assembly, Disc 303 SS C8964D C8964D C8964D C8964D
22 Seat 303 SS 62187A 62187A 62187A 62187A
23 Nut, Hex, Stem, Lower Bronze 6779806G 6779806G 6779806G 6779806G
24 Pipe Plug Bronze 6784701C 6784701C 6784701C 6784701C

FACTORY SET POINT 50 PSI 60 PSI 60 PSI 100 PSI

REPAIR KIT* 9170007A 9170007A 9170007A 9170007A

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2009 Printed in USA Specifications subject to change without notice. PL-CRL (R-2/09)
This page was intentionally left blank!
CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2008 Printed in USA Specifications subject to change without notice. PL-CK2 (R-1/08)
This page was intentionally left blank!
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
CV
Flow Control
DISASSEMBLY
Follow the sequence of the item numbers assigned to the
parts in the cross sectional illustration for recommended
order of disassembly.
Use a scriber, or similar sharp-pointed tool to remove O-ring
from the stem.

INSPECTION
Inspect all threads for damage or evidence of cross-
threading. Check mating surface of seat and valve disc for
excessive scoring or embedded foreign particles. Check
spring for visible distortion, cracks and breaks. Inspect all
parts for damage, corrosion and cleanliness.

CLEANING
After disassembly and inspection, cleaning of the parts can
begin. Water service usually will produce mineral or lime
deposits on metal parts in contact with water. These
deposits can be cleaned by dipping the parts in a 5-percent
muriatic acid solution just long enough for deposits to dis-
solve. This will remove most of the common types of
deposits. Caution: use extreme care when handling
acid. If the deposit is not removed by acid, then a fine grit
DESCRIPTION (400) wet or dry sandpaper can be used with water. Rinse
The Cla-Val Model CV Flow Control is a simply-designed, parts in water before handling. An appropriate solvent can
spring-loaded check valve. Rate of flow is full flow in one direc- clean parts used in fueling service. Dry with compressed air
tion and restricted in other direction. Flow is adjustable in the or a clean, lint-free cloth. Protect from damage and dust
restricted direction. It is intended for use in conjunction with a until reassembled.
pilot control system on a Cla-Val Automatic Control Valve.
REPAIR AND REPLACEMENT
OPERATION Minor nicks and scratches may be polished out using a fine
The CV Flow Control permits full flow from port A to B, and grade of emery or crocus cloth; replace parts if scratches
restricted flow in the reverse direction. Flow from port A to B cannot be removed.
lifts the disc from seat, permitting full flow. Flow in the reverse Replace O-ring packing and gasket each time CV Flow
direction seats the disc, causing fluid to pass through the clear- Control is overhauled.
ance between the stem and the disc. This clearance can be
increased, thereby increasing the restricted flow, by screwing Replace all parts which are defective. Replace any parts
the stem out, or counter-clockwise. Turning the stem in, or which create the slightest doubt that they will not afford com-
clockwise reduces the clearance between the stem and the pletely satisfactory operation. Use Inspection steps as a
disc, thereby reducing the restricted flow.’ guide.

INSTALLATION REASSEMBLY
Install the CV Flow Control as shown in the valve schematic Reassembly is the reverse of disassembly; no special tools
All connections must be tight to prevent leakage. are required.

TEST PROCEDURE
No testing of the flow Control is required prior to reassembly
to the pilot control system on Cla-Val Main Valve.

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2009 Printed in USA Specifications subject to change without notice.
N-CV (R-1/09)
 PARTS LIST

CV
3/8" Flow Control

ADJUSTING STEM
(TURN CLOCKWISE TO 1
INCREASE RESTRICTION)
7

2
2.12
MAX 10
STAMP PART NO. ON
SMOOTH SURFACE 9

8
RESTRICTED
FLOW 6

1.84 3/8 - 18 NPT

4

When ordering parts,

.85 please specify:
• Number Stamped on Side
• Description (CV Flow Control)
FREE FLOW • Part Description
• Material

ITEM DESCRIPTION QTY

1 Cap (SS only) 1
2 Nut, Jam 1
3 Seat 1
4 Gasket 1
5 Disc 1
6 Spring 1
7 Ring, Retaining 1
8 Stem 1
BAR STOCK 9 O-Ring 1
CONFIGURATION
10 Housing 1

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2009 Printed in USA Specifications subject to change without notice. PL-CV (R-1/09)
 Cla-Val Product
Identification
How to Order
Proper Identification
For ordering repair kits, replacement parts, or for
INLET SIZE &
inquiries concerning valve operation, it is important to CAT NO.

properly identify Cla-Val products already in service

EINTRITT STOCK
NO. CODE

by including all nameplate data with your inquiry. ENTREE

MFD. BY CLA-VAL
Pertinent product data includes valve function, size, ENTRADA NEWPORT BEACH, CALIF, U.S.A.

material, pressure rating, end details, type of pilot

This brass plate appears on valves sized 21/2" and larger
controls used and control adjustment ranges.
and is located on the top of the inlet flange.
Identification Plates
For product identification, cast-in body markings are
supplemented by identification plates as illustrated on
this page. The plates, depending on type and size of IN L E T
product, are mounted in the most practical position. It
is extremely important that these identification
plates are not painted over, removed, or in any
IN L E T
other way rendered illegible.

These two brass plates appear on 3/8", 1/2", and 3/4" size
valves and are located on the valve cover.

SIZE &
CAT NO.

RESERVOIR STOCK
NO.
CODE

END FLOW
MFD. BY CLA-VAL NEWPORT BEACH, CALIF. U.S.A.

These two brass plates appear on threaded valves

This brass plate appears on altitude valves only and is
found on top of the outlet flange. 1" through 3" size or flanged valves 1" through 2".
It is located on only one side of the valve body.

®
SIZE & SIZE & CODE
CAT NO. CAT NO.
C STOCK
STOCK
™ NO.
NO.
MFD. BY CLA-VAL
SPRING NEWPORT BEACH, CALIF.
RANGE U.S.A.

MFD. BY CLA-VAL NEWPORT BEACH, CALIF. U.S.A. This brass plate is used to identify pilot control valves.
The adjustment range is stamped into the plate.
This tag is affixed to the cover of the pilot control valve.
The adjustment range appears in the spring range section.

DO NOT REMOVE
REDUCED PRESSURE BACKFLOW PREVENTION DEVICE

THIS VALVE HAS BEEN MODIFIED -4 STK.

RP
CAT. NO.
SINCE ORIGINAL SHIPMENT FROM
FACTORY. WHEN ORDERING PARTS SER.
NO. NO.
AND/ OR SERVICE SUPPLY DATA FROM
THIS PLATE & ALL OTHER PLATES ON CLA-VAL NEWPORT BEACH, CA.

ORIGINAL VALVE.
This brass plate is used on our backflow prevention
® assemblies. It is located on the side of the Number Two
check (2" through 10"). The serial number of the
C assembly is also stamped on the top of the inlet flange of
™

the Number One check.

This aluminum plate is included in pilot system
modification kits and is to be wired to the new pilot
control system after installation.
 HOW TO ORDER SPECIFY WHEN ORDERING
• Model Number • Valve Size
Because of the vast number of possible configurations and • Globe or Angle Pattern • Threaded or Flanged
combinations available, many valves and controls are not • Adjustment Range • Body and Trim Materials
shown in published product and price lists. For ordering (As Applicable) • Optional Features
information, price and availability on product that are not listed, • Pressure Class
please contact your local Cla-Val office or our factory office
located at: UNLESS OTHERWISE SPECIFIED
• Globe or angle pattern are the same price
P. O. Box 1325 • Ductile iron body and bronze trim are standard
Newport Beach, California 92659-0325 • X46 Flow Clean Strainer or X43 “Y” Strainer are included
(949) 722-4800 • CK2 Isolation Valves are included in price on 4" and larger
FAX (949) 548-5441 valve sizes (6" and larger on 600 Series)

LIMITED WARRANTY
DISCLAIMER OF WARRANTIES AND
Automatic valves and controls as manufactured by Cla-Val are warranted
for three years from date of shipment against manufacturing defects in LIMITATIONS OF LIABILITY
material and workmanship that develop in the service for which they are The foregoing warranty is exclusive and in lieu of all other
designed, provided the products are installed and used in accordance warranties and representations, whether expressed, implied, oral or
with all applicable instructions and limitations issued by Cla-Val. written, including but not limited to any implied warranties or
Electronic components manufactured by Cla-Val are warranted for one merchantability or fitness for a particular purpose. All such other
year from the date of shipment. warranties and representations are hereby cancelled.
We will repair or replace defective material, free of charge, that is returned Cla-Val shall not be liable for any incidental or consequential loss,
to our factory, transportation charges prepaid, if upon inspection, the damage or expense arising directly or indirectly from the use of the
material is found to have been defective at time of original shipment. This product. Cla-Val shall not be liable for any damages or charges for
warranty is expressly conditioned on the purchaser’s providing written labor or expense in making repairs or adjustments to the product.
notification to Cla-Val immediate upon discovery of the defect. Cla-Val shall not be liable for any damages or charges sustained in
Components used by Cla-Val but manufactured by others, are warranted the adaptation or use of its engineering data and services. No
only to the extent of that manufacturer’s guarantee. representative of Cla-Val may change any of the foregoing or
assume any additional liability or responsibility in connection with
This warranty shall not apply if the product has been altered or repaired by the product. The liability of Cla-Val is limited to material
others, Cla-Val shall make no allowance or credit for such repairs or replacements F.O.B. Newport Beach, California.
alterations unless authorized in writing by Cla-Val.

TERMS OF SALE
ACCEPTANCE OF ORDERS RISK
All orders are subject to acceptance by our main office at Newport Beach, California. All goods are shipped at the risk of the purchaser after they have been delivered by
us to the carrier. Claims for error, shortages, etc., must be made upon receipt of
CREDIT TERMS
goods.
Credit terms are net thirty (30) days from date of invoice.
EXPORT SHIPMENTS
PURCHASE ORDER FORMS
Export shipments are subject to an additional charge for export packing.
Orders submitted on customer’s own purchase order forms will be accepted only
with the express understanding that no statements, clauses, or conditions contained RETURNED GOODS
in said order form will be binding on the Seller if they in any way modify the Seller’s 1. Customers must obtain written approval from Cla-Val prior to returning any
own terms and conditions of sales. material.
PRODUCT CHANGES 2. Cla-Val reserves the right to refuse the return of any products.
The right is reserved to make changes in pattern, design or materials when deemed
3. Products more than six (6) months old cannot be returned for credit.
necessary, without prior notice.
4. Specially produced, non-standard models cannot be returned for credit.
PRICES
All prices are F.O.B. Newport Beach, California unless expressly stated otherwise on 5. Rubber goods such as diaphragms, discs, o-rings, etc., cannot be returned for
our acknowledgement of the order. Prices are subject to change without notice. The credit, unless as part of an unopened vacuum sealed repair kit which is less
prices at which any order is accepted are subject to adjustment to the Seller’s price than six months old.
in effect at the time of shipment. Prices do not include sales, excise, municipal, state 6. Goods authorized for return are subject to a 35% ($75 minimum) restocking
or any other Government taxes. Minimum order charge $75.00. charge and a service charge for inspection, reconditioning, replacement of
RESPONSIBILITY rubber parts, retesting, repainting and repackaging as required.
We will not be responsible for delays resulting from strikes, accidents, negligence of 7. Authorized returned goods must be packaged and shipped prepaid to Cla-Val,
carriers, or other causes beyond our control. Also, we will not be liable for any 1701 Placentia Avenue, Costa Mesa, California 92627.
unauthorized product alterations or charges accruing there from.

CLA-VAL Represented By:

PO Box 1325 Newport Beach CA 92659-0325
Phone: 949-722-4800 Fax: 949-548-5441
CLA-VAL CANADA CLA-VAL EUROPE
4687 Christie Drive Chemin dés Mesanges 1
Beamsville, Ontario CH-1032 Romanel/
Canada LOR 1B4 Lausanne, Switzerland
Phone: 905-563-4963 Phone: 41-21-643-15-55
Fax: 905-563-4040 Fax: 41-21-643-15-50
©COPYRIGHT CLA-VAL 2007 Printed in USA
E-Product I.D. (R-12//07) Specifications subject to change without notice. www.cla-val.com
 INSTALLATION / OPERATION / MAINTENANCE

MODEL
REPAIR KITS

Complete Replacement Diaphragm Assemblies for 100-01 and 100-20 Hytrol Main Valves
For: Hytrol Main Valves with Ductile Iron, Bronze Trim Materials—125/150 Pressure Class Only.
FACTORY ASSEMBLED
Includes: Stem, Disc Guide, Disc, Disc Retainer, Spacer Washers, Diaphragm, Diaphragm Washer
and Stem Nut.

Valve Diaphragm Assembly Valve Diaphragm Assembly

Size Stock Number Size Stock Number
100-01 100-20 100-01 100-20
3/8" (Also 81-01 ) 49097K N/A 6" 40456G 33273E
1/2" - 3/4" (Also 81-01 ) C2518D N/A 8" 45276D 40456G
1" C2520K N/A 10" 81752J 45276D
1 1/4"-1 1/2" C2522 F N/A 12" 85533J 81752J
2" C2524B N/A 14" 89067D N/A
2 1/2" C2523D N/A 16" 89068B 85533J
3" C2525J C2524B 20" N/A 89068B
4" 33273E C2525J 24" N/A 89068B

Repair Kits for 100-01/100-20 Hytrol Valves

For: Hytrol Main Valves—125/150 Pressure Class Only.
Includes: Diaphragm, Disc (or Disc Assembly) and spare Spacer Washers.

Buna-N® Standard Material Viton (For KB Valves)

Valve Repair Kit Valve Repair Kit
Size Stock Number Size Stock Number
100-01 100-20 100-01 100-20
3/8" (Also 81-01 ) 9169801K N/A 3/8" (Also 81-01 ) 9169806J N/A
1/2" - 3/4" (Also 81-01 ) 9169802H N/A 1/2" - 3/4" (Also 81-01 ) 9169807G N/A
1" 9169803F N/A 1" 9169808E N/A
1 1/4" - 1 1/2" 9169804D N/A 1 1/4” - 1 1/2" 9169809C N/A
2" 9169805A N/A 2" 9169810A N/A
2 1/2" 9169811J N/A 2 1/2" 9169817F N/A
3" 9169812G 9169805A 3" 9169818D 9169810A
4" 9169813E 9169812G 4" 9169819B 9169818D
6" 9169815K 9169813E 6" 9169820K 9169819B
8" 9817901D 9169815K 8" 9169834A 9169820K
10" 9817902B 9817901D
12" 9817903K 9817902B
14" 9817904H N/A
16" 9817905E 9817903K
20" N/A 9817905E
24" 9817906C 9817905E

When ordering, please give complete nameplate data of the valve and/or control being repaired.
MINIMUM ORDER CHARGE APPLIES.
Repair Kits for 100-02/100-21 Powertrol and 100-03/100-22 Powercheck Main Valves
For: Powertrol and Powercheck Main Valves—125/150 Pressure Class Only
Includes: Diaphragm, Disc (or Disc Assembly) and O-rings and full set of spare Spacer Washers.
Valve Kit Stock Number Valve Kit Stock Number
Size 100-02 Size 100-02 & 100-03 100-21 & 100-22
⁄8”
3
9169901H 21⁄2” 9169910J N/A
1
⁄2” & 3⁄4” 9169902F 3” 9169911G 9169905J
1” 9169903D 4” 9169912E 9169911G
11⁄4” & 11⁄2” 9169904B 6” 9169913C 9169912E
2” 9169905J 8” 99116G 9169913C
10” 9169939H 99116G
12" 9169937B 9169939H
Repair Kits for 100-04/100-23 Hy-Check Main Valves Larger Sizes: Consult Factory.
For: Hy-Check Main Valves—125/150 Pressure Class Only
Includes: Diaphragm, Disc and O-Rings and full set of spare Spacer Washers.
Valve Kit Stock Number Valve Kit Stock Number
Size 100-04 100-23 Size 100-04 100-23
4” 20210901B N/A 12” 20210905H 20210904J
6” 20210902A 20210901B 14” 20210906G N/A
8” 20210903K 20210902A 16” 20210907F 20210905H
10” 20210904J 20210903K 20” N/A 20210907F
24” N/A 20210907F

Repair Kits for Pilot Control Valves (In Standard Materials Only) Larger Sizes: Consult Factory.
Includes: Diaphragm, Disc (or Disc Assembly), O-Rings, Gaskets or spare Screws as appropriate.

BUNA-N® (Standard Material) VITON (For KB Controls)

Kit Kit Kit
Pilot Pilot Pilot
Stock Stock Stock
Control Control Control
Number Number Number
CDB 9170006C CFM-7 1263901K CDB-KB 9170012A
CDB-30 9170023H CFM-7A 1263901K CRA-KB N/A
CDB-31 9170024F CFM-9 12223E CRD-KB (w/bucking spring) 9170008J
CDB-7 9170017K CRA (w/bucking spring) 9170001D CRL-KB 9170013J
CDH-2 18225D CRD (w/bucking spring) 9170002B CDHS-2BKB 9170010E
CDHS-2 44607A CRD (no bucking spring) 9170003K CDHS-2FKB 9170011C
CDHS-2B 9170004H CRD-18 20275401K CDHS-18KB (no bucking spring) 9170009G
CDHS-2F 9170005E CRD-22 98923G 102C-KB 1726202D
CDHS-3C-A2 24657K CRL (55F, 55L) 9170007A
CDHS-8A 2666901A CRL-4A 43413E
CDHS-18 9170003K CRL-5 (55B) 65755B
CDS-4 9170014G CRL-5A (55G) 20666E
CDS-5 14200A CRL-18 20309801C
CDS-6 20119301A CV 9170019F
CDS-6A 20349401C X105L (O-ring) 00951E Buna-N®
CFCM-M1 1222301C 102B-1 1502201F CRD Disc Ret. (Solid) C5256H
CFM-2 12223E 102C-2 1726201F CRD Disc Ret. (Spring) C5255K
102C-3 1726201F

Repair Assemblies (In Standard Materials Only)

Control Description Stock Number
CF1-C1 Pilot Assembly Only 89541H
CF1-Cl Complete Float Control less Ball and Rod 89016A
CFC2-C1 Disc, Distributor and Seals 2674701E
CSM 11-A2-2 Mechanical Parts Assembly 97544B
CSM 11-A2-2 Pilot Assembly Only 18053K
33A 1" Complete Internal Assembly and Seal 2036030B
33A 2" Complete Internal Assembly and Seal 2040830J
When ordering, please give complete nameplate data of the valve and/or control being repaired. MINIMUM ORDER CHARGE APPLIES

CLA-VAL P.O. Box 1325 • Newport Beach, CA 92659-0325 • Phone: 949-722-4800 • Fax: 949-548-5441 • E-mail: claval@cla-val.com • Website cla-val.com
©
Copyright Cla-Val 2009 Printed in USA Specifications subject to change without notice. N-RK (R-4/09)