IMO - 203EN Issue Date: 2/04

INSTALLATION, MAINTENANCE, AND

OPERATING INSTRUCTIONS

2-1/2" (DN 65)

REDUCED BORE
2" (DN 50) FULL BORE
SERIES 4000 3-PIECE
BALL VALVES

Read entire instructions carefully before installation or servicing

1 GENERAL 2 INSTALLATION
This instruction manual contains important information 1. Screwed End Style - Use standard piping practices to
regarding the installation, operation and troubleshooting install valves with threaded end caps.When tightening
of the Jamesbury® 2-1/2" (DN 65) Reduced Bore and 2" valve to pipe, apply wrench to end cap nearest the
(DN 50) Full Bore Series 4000 3-Piece Ball Valves. Please pipe being worked.
read these instructions carefully and save them for future
reference. 2. Weld End Style - All standard weld end valves must
be partially disassembled prior to welding. Follow
steps 1, 2, 4, and 5 of the DISASSEMBLY Section.
1.1 WARNING Socket weld ends are per ANSI B16.11, and butt weld
FOR YOUR SAFETY, TAKE THE FOLLOWING PRECAUTIONS BEFORE ends are per ANSI B16.25. Welding should be done
REMOVING THE VALVE FROM THE LINE OR BEFORE ANY DISASSEMBLY: using procedures and welders qualified under Section
IX of the ASME Boiler and Pressure Vessel Code.
1. DURING REMOVAL AND DISASSEMBLY, WEAR ANY PROTECTIVE
EQUIPMENT NORMALLY REQUIRED TO PROTECT AGAINST DIS- IMPORTANT: If the two body seals (6) are removed for
CHARGE OF TRAPPED FLUID. welding, do not mix them. When reassembling the
valve, put each seal back in the groove from which it
2. DEPRESSURIZE THE LINE AND VALVE AS FOLLOWS:
was removed.
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE
LINE. CAUTION: WHEN THE VALVE IS BEING DISASSEMBLED
FOR WELDING, DO NOT CUT OR SCRATCH THE SEATS,
B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE BODY
CAVITY BEFORE REMOVAL FROM THE LINE.
SEALS AND SEALING SURFACES.

C. AFTER REMOVAL, AND BEFORE ANY DISASSEMBLY, CYCLE THE 3. After valve is in line. or before testing, tighten stem
VALVE AGAIN SEVERAL TIMES. nuts (16) according to the MAINTENANCE Section.
3. SEAT AND BODY RATINGS - THE PRACTICAL AND SAFE USE OF
THIS PRODUCT IS DETERMINED BY BOTH THE SEAT AND BODY
3 MAINTENANCE
RATING. READ THE NAME TAG AND CHECK BOTH RATINGS. THIS Routine maintenance consists of tightening the stem nut
PRODUCT IS AVAILABLE WITH A VARIETY OF SEAT MATERIALS. 1/4 turn periodically to compensate for the wear caused by
SOME OF THE SEAT MATERIALS MAY HAVE PRESSURE RATINGS the stem turning against the stem seals. When tightening
THAT ARE LESS THAN THE BODY RATINGS. ALL OF THE BODY AND
SEAT RATINGS ARE DEPENDENT ON VALVE TYPE AND SIZE, SEAT
stem seals on actuated valves where the valve is connected
MATERIAL AND TEMPERATURE. DO NOT EXCEED THESES RATINGS. to the actuator with a no-play (clamped) coupling, loosen
the coupling before tightening the stem nut. Re-tighten
the coupling. Overhaul maintenance consists of replacing
2

seats and seals. A standard service kit consisting of these 9. Press the stem (4) from the top into the valve body (1),
parts may be obtained from your Metso Automation and remove it through the end of the body.
Distributor or representatives (see Table 2).
10. Carefully pry out and discard the old stem seals (7), the
3.1 Disassembly stem bearings (8), and the secondary seal (13) being
careful not to damage the bearing surfaces.
The Series 4000 ball valve is designed to be serviced in or
out of the line.The following instructions are for in-line dis- 3.2 Assembly
assembly. (For bench disassembly, which may be more
convenient, follow a similar sequence.) The following instructions are for in-line assembly. For
bench assembly, which may be more convenient, follow a
1. Comply fully with the instructions in the WARNING similar sequence by holding the valve in a vise by one end
Section. cap. Use care not to cut or scratch the seats, seals or seal-
2. Be sure to cycle the valve. Leave in the open position.The ing surface.
body center section will not swing out in the closed 1. With the valve swung to the out-of-line position, insert
position. from the inside of the body a stem bearing (8), a sec-
3. Remove the cap screw (21) and the handle (15). ondary seal (13), then another stem bearing (8) into
the stem bore.
4. Loosen all eight body bolts (20). Pick two bolts (closest
to the top of the valve) that are in line and opposite 2. Insert the stem (4) horizontally into the body bore
each other, and back them off at least 5/16”. Remove (threaded end first). The blade at the ball end of the
the remaining six bolts. stem must be vertical (see Figure 2A and B). Guide
the stem into the stem hole being careful not to
5. For positive alignment and ease of in-line assembly, each
scratch the bearings.
end cap is interlocked approximately 3/32” (2.4 mm)
into the body as shown in (Figure 3). To overcome this
feature during in-line disassembly,it is necessary to sep-
arate each cap at least 3/32” (2.4 mm) from the body.
Sharply rap body and caps with a block of wood or
plastic mallet to break the body seal loose. Spread end
caps and swing the body out of the line. If the pipe does
not allow simple spreading, remove the remaining body Figure 2A Figure 2B
bolts and rotate center section per (Figure 1). This will
improve access to the end cap flange for ease of spread- Surface A
8
ing. Swing the valve body (1) out from between the end 13 Surface A
caps (2). Be careful not to damage the sealing surfaces "A"
(see Figure 3) at each end of the valve.

3/32” (2.4 mm)

Interlock

Figure 3

3. Holding the stem in place from the bottom, install the

Figure 1 top stem seal (7), a compression ring (18), indicator
stop (12), Shakeproof washer (9), and thread on stem
6. Turn the stem (4) so that the valve is fully closed. nut (16) until the stem starts to turn.
Remove body seals (6) and seats (5). Body seals may be 4. Place a wrench through the body on the bottom stem
tightly compressed in their grooves. Use extreme care blade to hold the stem stationary. Place another
when prying them out. Damage such as scratches to wrench on the stem nut and turn the nut down until
the bottom of the groove will cause leaks. If the seats the seals are bottomed and the stem comes snugly into
are not easily removed, gently tap the ball (3) with a place. Tighten an additional 1/4 to 1/2 turn.
piece of wood or other soft material.
5. Align the stem blade with the ball slot. Insert the ball (3)
7. Remove the ball (3).
and rotate the stem (4) to the ball closed position.
8. Remove and save the stem nut (16), Shakeproof® washer
(9), indicator stop (12), and compression ring (18). (text continued on page 4)
 3
PARTS LIST TABLE 1
ITEM PART NAME QTY
REQUIRED FASTENER TORQUES, FT•LBS (N•m)
1 Body 1
2 Body Cap 2 Fastener
3 Ball 1 -1 -2 -4 -5 -7 -8
(Last Digit in Figure No.)
4 Stem 1
5 Seat 2 Fastener A193 A194 K- A193 A320 A453
6 Body Seal 2 Valve Size - Material GR.B7 GR.B8 Monel®+ GR.B7M GR.L7M GR.660
7 Stem Seal 1
Full Port Fastener 660A
8 Stem Bearing 2
9 Shakeproof® Washer 1 Size IN ( ) Ident. B7 B8 K B7M L7M or
12 Indicator Stop 1 Mark 660B
13 Secondary Stem Seal 1 FT•LBS 74 – 93 71 – 89 64 – 80 60 – 75 57 – 71 60 – 75
Body Bolt
15 Handle 1
16 Stem Nut 1 Torque N•m 100 – 126 96 – 121 87 – 108 81 – 102 77 – 86 81 – 102
18 Compression Ring 1
20 Body Bolt 8 NOTES:
21 Hex Cap Screw 1 1. Lubricate threads with Never-Seez® or equivalent.
25 Weld End Tag* 1
2. Fastener materials have different corrosion, thermal and strength properties and should
29 Identification Plate 1
38 Socket Head Screw 1 not be mixed. The fastener identification and coding must be in agreement with the valve
Identification Plate, item 29.
* Socket weld or butt weld only.
+ Monel is a registered trademark of INCO.

Outside of Valve

15

21

16

20 Bolts Ball
9
12
2 ORIENTATION OF
V-RING SEALS

38 18

1
3

5
6
6
5
2
29

8
13

4
4

6. Working at either end of the body (1), place a seat (5) 4 SERVICE KITS
into the body. Fit it snugly against the closed ball.
NOTE: The sealing surface of the seat is toward the ball NOTE: FIRE-TESTED service kits include two seats (5), one
(See Figure 3). stem seal (7), two stem bearings (8), a secondary seal (13)
and two 316 stainless steel/graphite body seals (6). The
7. Place a body seal (6) into the machined sealing groove body seals are suitable for valves with carbon steel or 316
of the end cap (2) (See Figure 3). Be certain the groove stainless steel trim.
and seal are clean.
8. Repeat instructions 6 and 7 for assembly at the oppo-
5 REPAIR KITS/SPARE PARTS
site end. For further information on spare parts and service or assis-
9. Turn the stem to the full ball open position. tance visit our web-site at www.jamesbury.com.

10. Swing the entire body assembly back into the properly
aligned and interlock position between the end caps,
being careful not to scratch the body seals. Caps may
have to be spread slightly to accept the body. TABLE 2
Service Kits For Fire-Tested Valves
11. Close the valve. PTFE Seats RKN-150-TT
12. Bolt the valve together with lubricated body bolts (20). Filled PTFE Seats RKN-150-MT
Using a calibrated torque wrench, tighten these bolts Peek Seats RKN-150-LT
evenly and alternately. (See Table 1 for the torques Metal Seats RKN-150-DH
and lubricant.) Failure to properly tighten the bolting Xtreme® Seats RKN-150-XT
may result in leakage. Service Kits For Non-Fire-Tested Valves
PTFE Seats RKN-151-TT
13. Attach the handle (15); secure it with the cap screw. Filled PTFE Seats RKN-151-MT
14. On manual valves be sure item (38), socket head cap UHMW Poly Seats RKN-151-UB
screw, is not loose. Xtreme Seats RKN-151-XT

25

Metso Automation, Field Systems Division

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www.jamesbury.com

IMO-203EN-2/04 © 2004 Metso Automation Printed in U.S.A.-J-J