Series 4000 Model A

3-Piece Ball Valves

1/2" - 2" (DN 15 - 50)

Installation, Maintenance and

Operating Instructions

IMO-202EN • 1/2012
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Table of Contents
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 REPAIR KITS/SPARE PARTS . . . . . . . . . . . . . . . . . . . . 6

READ THESE INSTRUCTIONS FIRST!

This instruction manual contains important information regarding the installation, operation, and troubleshooting
of the Jamesbury® 1/2" to 2" Series 4000 Model A Three-Piece Ball Valves. Please read these instructions carefully
and save them for future reference.

SAVE THESE INSTRUCTIONS!

Subject to change without notice.

IMO-202EN 3

1 GENERAL 3 MAINTENANCE
This instruction manual contains important information Routine maintenance consists of tightening the lower stem
nut 1/4 turn periodically to compensate for the wear caused
regarding the installation, operation and maintenance of the by the stem turning against the stem seals. The upper stem
Jamesbury 1/2" – 2" (DN 15 – 50) Series 4000 3 Piece Ball nut should be tightened a corresponding amount. When
Valves. Please read these instructions carefully and save them tightening stem seals on actuated valves, where the valve is
for future reference. connected to the actuator with a no-play (clamped) coupling,
loosen the coupling before tightening the stem nut.
Retighten the coupling. Overhaul maintenance consists of
1.1 WARNING replacing seats and seals. A standard service kit consisting of
FOR YOUR SAFETY, TAKE THE FOLLOWING PRECAUTIONS BEFORE these parts may be obtained from your Jamesbury Distributor
REMOVING THE VALVE FROM THE LINE, OR BEFORE ANY DISASSEMBLY: (see Table 3).
1. DURING REMOVAL AND DISASSEMBLY, WEAR ANY PROTECTIVE
EQUIPMENT NORMALLY REQUIRED TO PROTECT AGAINST
3.1 Disassembly
DISCHARGE OF TRAPPED FLUID. The Series 4000 ball valve is designed to be serviced in or
2. DEPRESSURIZE THE LINE AND VALVE AS FOLLOWS:
out of the line.The following instructions are for in-line dis-
assembly. (For bench disassembly, which may be more
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE
LINE.
convenient, follow a similar sequence).

B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE 1. Comply fully with the instructions in the WARNING
BODY CAVITY BEFORE REMOVAL FROM THE LINE. Section on page one.
C. AFTER REMOVAL, AND BEFORE ANY DISASSEMBLY, CYCLE THE 2. Be sure to cycle the valve. Leave in the open position.
VALVE AGAIN SEVERAL TIMES.
The body center section will not swing out in the
3. SEAT AND BODY RATINGS - THE PRACTICAL AND SAFE USE OF closed position.
THIS PRODUCT IS DETERMINED BY BOTH THE SEAT AND BODY
RATING. READ THE NAME TAG AND CHECK BOTH RATINGS. THIS 3. Remove the top stem nut (16), Shakeproof Washer (19)
PRODUCT IS AVAILABLE WITH A VARIETY OF SEAT MATERIALS. and handle (17).
SOME OF THE SEAT MATERIALS HAVE PRESSURE RATINGS THAT
ARE LESS THAN THE BODY RATINGS. ALL OF THE BODY AND 4. Loosen all four body bolts/tie rods (52). Remove three
SEAT RATINGS ARE DEPENDENT ON VALVE TYPE AND SIZE, from the valve. Leave the remaining bolt in place with
SEAT MATERIAL, BOLTING MATERIAL, AND TEMPERATURE.
DO NOT EXCEED THESE RATINGS. the nut backed off at least 1/4" (6mm).
NOTE: OPTIONAL ROUND AND OVAL HANDLES ARE AVAILABLE FOR 5. For positive alignment and ease of in-line assembly, each
THESE VALVES IN PLACE OF LEVER HANDLES. end cap is interlocked approximately 1/16" (1.6 mm)
into the body as shown in (Figure 3).To overcome this
feature during in-line disassembly it is necessary to
2 INSTALLATION separate each cap at least 1/16" (1.6 mm) from the
body. Sharply rap body and caps with a block of wood
1. Screwed End Style - Screwed end valves have NPT
threads.To insure a leaktight joint, liberal use of a compat-
or plastic mallet to break loose body seal. Spread end
ible pipe joint compound is necessary. Use standard pip- caps and swing the body out of the line. If pipe does
ing practices to install valves with threaded end caps.
When tightening valve to pipe, apply wrench to end cap
nearest the pipe being worked.
2. Weld End Style - All standard weld end valves must be
partially disassembled prior to welding. Follow Steps 1, 2,
4 and 5 of DISASSEMBLY Section. Socket weld ends are
per ANSI B16.11 and butt weld ends are per ANSI B16.25.
Welding should be done using procedures and welders
qualified under Section IX of the ASME Boiler and Pressure
Vessel Code. IMPORTANT: If the body seals (6) are
removed for welding, DO NOT MIX THEM. When
reassembling the valve, put each seal back into the
groove from which it was removed. Figure 1
CAUTION: IF THE VALVE IS BEING DISASSEMBLED FOR WELDING.
DO NOT CUT OR SCRATCH THE SEATS, SEALS AND SEALING
SURFACES.
3. After valve is in line, or before testing, tighten stem nuts
(16) according to the MAINTENANCE Section below.

Figure 2A Figure 2B
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not allow simple spreading, remove the remaining 3. Holding the stem in place from the bottom, install two
body bolt and rotate center section per (Figure 1). This stem seals (8), a compression ring (21) from the outside
will improve access to the end cap flange for ease of and thread on one stem nut (16) until the stem starts
spreading. Swing the valve body (1) out from between to turn.
the end caps (2). Be careful not to damage the sealing
4. Place a wrench through the body on the bottom stem
surfaces “A” (see Figure 3) at each end of the valve.
blade to hold the stem stationary. Place another
6. Turn the stem (4) so that the valve is fully closed. wrench on the stem nut and turn the nut down until
Remove body seals (6) and seats (5). Body seals may be the seals are bottomed and the stem comes snugly
tightly compressed in their grooves. Use extreme care into place, applying the torque shown in (Table 2).
when prying them out. Damage such as scratches to
5. Align the stem blade with the ball slot. Insert the ball
the bottom of the groove will cause leaks. If the seats
(3), and rotate the stem (4) to the ball closed position.
are not easily removed, gently tap the ball (3) with a
piece of wood or other soft material. 6. Working at either end of the body (1), place a seat (5)
7. Remove the ball (3). into the body. Fit it snugly against the closed ball.
NOTE: The sealing surface of the seat is toward the ball
8. Remove the lower stem nut (16) and the compression
(See Figure 4).
ring (21).
7. Place a body seal (6) into the machined sealing groove
9. Press the stem (4) from the top into the valve body (1) of the end caps (2) (see Figure 3). Be certain the
and remove it through the end of the body. groove and seal are clean.
10. Carefully pry out and discard the old stem seals (8), the 8. Repeat instructions 6 and 7 for assembly at the opposite
stem bearings (24), and the secondary stem seal (7), end.
being careful not to damage the bearing surfaces.
9. Turn the stem to the full ball open position.
3.2 Assembly 10. Swing the entire body assembly back into the properly
The following instructions are for in-line assembly. For aligned and interlock position between the end caps,
bench assembly, which may be more convenient, follow a being careful not to scratch the body seals. Caps may
similar sequence by holding the valve in a vise by one end cap. have to be spread slightly to accept the body.
Use care not to cut or scratch the seats,seals or sealing surface.
11. Close the valve.
1. With the valve swung to the out-of-line position, insert
from the inside of the body a stem bearing (24), a sec- 12. Bolt the valve together with lubricated body bolts (52) and
ondary stem seal (7), then another stem bearing (24) nuts (53). Tighten these bolts evenly and alternately.
into the stem bore. For non Fire-Tested valves use one (See Table 1 for the torques and lubricant.)
stem bearing (24). (See Figure 3 and parts list.) 13. Attach the handle (17), the Shakeproof Washer (19)
2. Insert the stem (4) horizontally into the body bore and secure them with the stem nut (16) (See Table 2
(threaded end first). The blade at the ball end of the for torques).
stem must be vertical (see Figure 2A and 2B). Guide
the stem into the stem hole being careful not to
scratch the bearings.

Surface A Surface A

1/16" (1.6 mm)

Interlock

FIRE-TESTED NON FIRE-TESTED

Figure 3
IMO-202EN 5

TABLE 1
Required Fastener Torque, FT•LBS (N•m)
Fastener (Last Digit in Fig. No.) -1 -2 -4 -5 -7 -8 -3

A193 A193 A193 A320 A453 Series

Valve Size-Full Port Fastener Material K-Monel® 300
GR.B7 GR.B8 GR.B7M GR.L7M GR.660
Size in( ) St.Sd.

Fastener ident. Mark 660A OR

B7 B8 K B7M L7M 660B

1/2" (1/2") DN 15 (DN15) 9 (12) 9 (12) 8 (11) 7 (9.5) 7 (9.5) 7 (9.5) 5 (7)
3/4" DN 20 20 (27) 18 (23) 17 (23) 15 (20) 15 (20) 15 (20) 9 (12)
1" (3/4") DN 25 (DN 20) 35 (49) 32 (43) 30 (40) 28 (38) 25 (34) 28 (38) 15 (20)
1-1/4" (1") DN 30 (DN 25) 40 (54) 37 (50) 35 (47) 32 (43) 30 (40) 32 (43) 18 (24)
1-1/2" (1-1/4") DN 40 (DN 30) 80 (119) 80 (110) 70 (95) 70 (95) 65 (90) 70 (95) 40 (54)
2" (1-1/2") DN 50 (DN 40) 100 (135) 90 (120) 80 (110) 75 (100) 70 (95) 75 (100) 45 (60)
NOTES:
1. Lubricate threads with Never-Seez® or equivalent.
2. Fastener materials have different corrosion, thermal and strength properties and should not be mixed. The fastener identification and
coding must be in agreement with the valve identification plate, item 22.
3. Torque valves are for lubricated, unplated fasteners.
Monel is a registered trademark of Inco.

TABLE 2
Stem Nut Torque
Valve Size - Full Port Size In ( ) FT•LBS (N•m)
1/2" – 3/4" (1/2") 4 (5.7)
1" – 1-1/4" (3/4" – 1") 5 (6.8)
1-1/2" – 2" (1-1/4" – 1-1/2") 11 (15.3)

TABLE 3
Service Kits Valve Size - Full Port Size Shown in ( ) FOR FIRE -TESTED VALVES
1/2" (1/2") 3/4" 1" (3/4") 1-1/4" (1") 1-1/2" (1-1/4") 2" (1-1/2")
VALVE SIZE
DN 15 (DN 15) DN 20 DN 25 (DN 20) DN 30 (DN 25) DN 40 (DN 30) DN 50 (DN 40)
PTFE SEATS RKN-107-TT RKN-108-TT RKN-109-TT RKN-110-TT RKN-111-TT RKN-112-TT
FILLED PTFE SEATS RKN-107-MT RKN-108-MT RKN-109-MT RKN-110-MT RKN-111-MT RKN-112-MT
DELRIN® SEATS RKN-107-RT RKN-108-RT RKN-109-RT RKN-110-RT RKN-111-RT RKN-112-RT
PEEK SEATS RKN-107-LT RKN-108-LT RKN-109-LT RKN-110-LT RKN-111-LT RKN-112-LT
METAL SEATS RKN-107-DH RKN-108-DH RKN-109-DH RKN-110-DH RKN-111-DH RKN-112-DH
XTREME® SEATS RKN-107-XT RKN-108-XT RKN-109-XT RKN-110-XT RKN-111-XT RKN-112-XT

TABLE 3
Service Kits Valve Size - Full Port Size Shown in ( ) FOR NON FIRE -TESTED VALVES
1/2" (1/2") 3/4" 1" (3/4") 1-1/4" (1") 1-1/2" (1-1/4") 2" (1-1/2")
VALVE SIZE
DN 15 (DN 15) DN 20 DN 25 (DN 20) DN 30 (DN 25) DN 40 (DN 30) DN 50 (DN 40)
PTFE SEATS RKN-137-TT RKN-138-TT RKN-139-TT RKN-140-TT RKN-141-TT RKN-142-TT
FILLED PTFE SEATS RKN-137-MT RKN-138-MT RKN-139-MT RKN-140-MT RKN-141-MT RKN-142-MT
UHMW POLY SEATS RKN-137-UB RKN-138-UB RKN-139-UB RKN-140-UB RKN-141-UB RKN-142-UB
XTREME SEATS RKN-137-XT RKN-138-XT RKN-139-XT RKN-140-XT RKN-141-XT RKN-142-XT
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PARTS LIST
ITEM PART NAME QTY
1 Body 1
2 End Cap 2
3 Ball 1
4 Stem 1
5 Seat 2
16 6 Body Seal 2
19 7 Secondary Stem Seal 1
8 Stem Seal 2
17
16 Stem Nut 2
17 Handle 2
16 19 Shakeproof Washer 1
2 21 Compression Ring 2
21 22 Identification Ring 1
(Socket Weld or 24* Stem Bearing 1
8 Butt Weld Only) 52 Body Bolt / Tie Rod 4
6 54 53 Body Nut 4/8
52 5 54 Weld End Tag 1
Bolts or * For Non Fire-Tested valves, items (24)
Tie Rods 1 and (7) are replaced by a single stem
bearing (24). (See Figure 3.)

3
5
6
13 2
24

22
4

NON FIRE-TESTED

53

Figure 4

4 REPAIR KITS/SPARE PARTS

NOTE: FIRE-TESTED service kits include two seats (5), two NOTE: NON FIRE-TESTED service kits include two seats
stem seals (8), two stem bearings (24), a secondary seal (7) (5), one stem bearing (24) and two body seals (6).The body
and two 316 stainless steel/graphite body seals (6). The seals are suitable for valves with carbon steel or 316 stain-
body seals are suitable for valves with carbon steel or 316 less trim.
stainless trim. Consult the factory for replacement parts of For further information on spare parts and service or assis-
valves with trim other than carbon or stainless steel, and for tance visit our web-site at www.metso.com/valves.
seat material not listed or for special services.
IMO-202EN 7
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Subject to change without prior notice.

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www.metso.com/valves