Jflow controls DM4800 SERIES Handbuch

JFLOW SERIES VALVES

(DM4800 SERIES)

METAL SEATED BALL VALVE

INSTALLATION – MAINTENANCE MANUAL

Document No: DM4800 MS

Date: 2010-02-01

Version: 1

PREPARED BY ATE_______________ D __________

REVIEWED BY DATE_______________ __________

APPROVED BY DATE_______________ __________

www.jﬂowcontrols.com

sales@jﬂowcontrols.com

J Flow Controls

4665 Interstate Dr.

Cincinna, OH 45246

Toll Free: 866-95-JFLOW (53569)

Local: 513-330-6354

Fax: 513-731-6939

DM 4800 Series MS Ball Valve

Installaon – Maintenance Manual

Document #: IM-DM4800 MS-01

Rev Date: 2010-02-01

Installaon & Maintenance for J Flow DM4800 Series Metal Seated Ball Valve

General Informaon

The J Flow DM4800 series metal seated ball valve has

been designed and engineered to provide a long

lasng, worry-free valve service when installed

according to the instrucons and speciﬁcaons given in

this manual. If repairs need to be made, only use

genuine J Flow Controls parts which are readily

available for immediate shipment (See Table B).

The following set of instrucons refers only to the

J Flow DM4800 MS series ball valve. Please contact

J Flow Controls if this is not the valve series in your

possession.

J Flow Controls is commi ed to providing The Right

Valve for the Right Applicaon, Right Now.

Delivery Condion and Storage

Manual valves will be shipped in the open posion.

Incoming quality control should check both the packing

condion to see if there is any damage during

transportaon and to make sure the bolts on the valve

and its stem are not loose.

When storing the valves, make sure to leave the valve in

the fully open or fully closed posion. This will prevent

damage to the seat due to contact with the balls edge.

Make sure to keep protecve cover in place to prevent

damage to the ball surface. It is highly recommended

that valves be stored indoors in a clean and dry

environment unl ready for use.

Safety Precauons

To prevent injury to yourself, others, or equipment,

make sure to read this secon in its enrety before

performing any installaon or operaon of this valve.

The pressure rangs of the valve are based on a variety

of elements, including valve series, size, body, seats,

and bolt material. Verify that your applicaon does not

exceed pressure or temperature rangs on the

nameplate of the valve.

Make sure to ALWAYS depressurize the line with your

valve in the full open posion before disassembly of the

valve. Cycle the valve in the depressurized line before

removing the valve.

Always wear protecve equipment and take

appropriate precauons to safeguard against injury

caused by discharge of trapped ﬂuids.

Only use J Flow Controls approved spare parts for

maintenance on any J Flow Controls valve. A complete

spare parts list is given in Table B.

As to ensure your safety and maintain warranty, do not

modify the valve in any way without prior approval

from J Flow Controls.

Installaon

The valve may be installed in either direcon. Prior to

installaon, be certain the valve is in the full open

posion. The pipe should be ﬂushed of any media that

could damage the ball or seats. If being welded, as long

as the DM4800 MS ball valve is in the open posion,

the valve does not have to be disassembled.

Operation

J Flow Controls valves provide tight shut off when

used under normal conditions and in accordance

with J Flow Controls published pressure and

temperature chart. All valves are provided

standard with a locking device for either the open or

closed position. It is advised to never leave the

valve in a partially open position as seat life can be

reduced.

J Flow Controls DM4800 MS series are a ¼ turn

valve which closes in the clockwise direction. The

valves handle points at the ﬂow direction, so when

the handle is in line with the pipeline, the valve is

open. Subsequently, when the handle is parallel to

the pipeline, the valve is closed. There is also a

notch on the valve stem indicating ﬂow as well.

Make sure when installing an actuator that the

position of the valve matches the actuator.

Media which may solidify, crystallize or polymerize

should never be allowed to remain in the ball valve

cavies unless regular maintenance is performed.

Maintenance

J Flow Controls valves are designed to easily be

disassembled and reassembled in the ﬁeld for easy

service. It is imperave that before compleng any

maintenance on a J Flow Controls valve, that the Safety

Precauons secon of this I&M is reviewed.

Ball valves normally do not require an internal lubricant

or roune maintenance once installed. Packing can be

adjusted if the valve has stem leakage or if the stem

seems loose. See the Troubleshoong secon of this

I&M for more informaon.

Internal maintenance by replacing the packing, seats,

seals, ball, or stem if any piece is damaged will require

disassembly (see Valve Disassembly).

Troubleshoong

STEM LEAKAGE

Examine the disk springs for damage. If they are in good

condion, then ghten the gland nut unl disk springs

are ﬁrmly compressed, then back nut oﬀ 1/16th of a

turn. If damaged, take apart the stem down to the

gland, ﬁt new disk springs with their outer edges

touching, replace and reghten with the stem nut. Any

further maintenance will require the dismantling of the

valve.

LEAKAGE AT BODY JOINT

Check to see if the body connector bolts have been

ghtened. If loose, ghten body bolts according to the

torque requirements given in Table A. If valve sll leaks,

the valve has to be disassembled and body seals will

need replaced.

IN-LINE LEAKAGE

Posion the valve in the closed posion. If leakage

occurs while the valve is closed, ball sealant surface or

seat could be damaged and the valve will have to be

disassembled.

www.jﬂowcontrols.com

sales@jﬂowcontrols.com

J Flow Controls

4665 Interstate Dr.

Cincinna, OH 45246

Toll Free: 866-95-JFLOW (53569)

Local: 513-330-6354

Fax: 513-731-6939

DM 4800 Series MS Ball Valve

Installaon – Maintenance Manual

Document #: IM-DM4800 MS-01

Rev Date: 2010-02-01

Installaon & Maintenance for J Flow DM4800 Series Metal Seated Ball Valve

Valve Disassembly

Before beginning any maintenance, make sure to read

the Safety Precauons secon of this I&M.

Note: An exploded view of valve parts is available at the

end of this I&M.

1. To inspect and/or replace body seals, seats, packing,

and/or ball, the valve must be in the open posion with

no ﬂow through the valve and removed from pipeline.

2. With the valve in the open posion, undo Body Bolts

(6) to separate valve Body (1) and End Caps (2).

3. Remove the Seats (5), Housing Seal (19), Back-up Seal

(20), Disk Spring (5A), and Gasket (3).

4. Turn valve in the closed posion so the Ball (4) can be

taken out from the Body (1).

5. Remove Handle Nut (15), Handle (18), Spacer (14),

and Nut Stop (13).

6. Remove the Stem Nut (12) to remove Disk Washers

(11), Gland Washer (10), and Stem Packing (9).

8. Push the Stem (8) down into the body cavity to

remove. Once removed take oﬀ the Thrust Washer (7)

and Half Split Rings (8A).

When the valve is disassembled, be sure to clean and

examine all valve parts.

1. Ball surface should be free from defects, and if any

are found, ball should be replaced. Using a defecve

ball will severely impair the valve performance.

2. The replacement of valve seats is recommended.

3. Stem seals and body seals (including the thrust

washer) should be discarded and replaced.

4. Aer cleaning the rest of the valve parts, examine

them for wear, corrosion, or mechanical damage.

Replace any defecve parts.

Recommended spare manufacturers parts are

indicated by an asterisk on Table B by the part name,

numbered by the exploded view at the end of this I&M.

Be sure to specify the exact valve part number to

ensure the correct parts are ordered.

J Flow Controls does not take responsibility for

incorrectly ordered spare parts.

Valve Reassembly

1. Apply an adequate amount of lubricant, that is

compable with the media being handled, around the

Ball (4), Seats (5), Housing Seal (19), Back-up Seal (20),

Disk Spring (5A), Gasket (3), Stem (8), and Thrust

Washer (7).

2. For stem reassembly, disassembly procedure should

be followed in reverse order.

3. When stem assembly is complete, ghten Stem Nut

(12) according to the values on Table A.

4. With the Stem (8) in the closed posion, insert the

Ball (4) into the Body (1) so that stem slot engages with

the slot at the base of the stem.

5. Insert Seats (5), Housing Seal (19), Back-up Seal (20),

Disk Spring (5A), and Gasket (3) into the Body (1).

6. Place End Caps (2) on either side of the Body (1).

7. Insert and ﬁnger ghten Body Bolts (6) diagonally, in

accordance to the cross pa ern procedure to Body (1).

8. In the ﬁnal assembly step ensure that body bolts are

ghtened accordinglyto the torques values in Table A.

9. Replace Nut Stop (13), Spacer (14), Handle (18), and

Handle Nut (15) then ghten .

www.jﬂowcontrols.com

sales@jﬂowcontrols.com

J Flow Controls

4665 Interstate Dr.

Cincinna, OH 45246

Toll Free: 866-95-JFLOW (53569)

Local: 513-330-6354

Fax: 513-731-6939

DM 4800 Series MS Ball Valve

Installaon – Maintenance Manual

Document #: IM-DM4800 MS-01

Rev Date: 2010-02-01

Installaon & Maintenance for J Flow DM4800 Series Metal Seated Ball Valve

Tesng

Aer compleng the reassembly of the valve, check

that it operates smoothly by cycling the valve open and

closed several mes.

If the enre valve was removed from the pipeline, test

the valve to appropriate speciﬁcaons.

Table A: DM4800 MS Bolt and Stem Nut Torque Data

Size Bolt Torque (in/lbs) Stem Nut Torque (in/lbs)

1/4" 88.50 70.80

3/8" 88.50 70.80

1/2" 88.50 70.80

3/4" 132.75 106.20

1" 132.75 106.20

1-1/4" 230.10 132.75

1-1/2" 230.10 132.75

2" 424.85 132.75

2-1/2" 424.85 132.75

3" 548.75 265.50

Table B: DM4800 MS Spare Parts List

Item# Qty Part Name Item# Qty Part Name

1 1 Body 10 1 Gland Washer*

2 2 End Cap 11 2 Disk Washer*

3 2 Gasket* 12 1 Stem Nut

41 Ball 131 NutStop

5 2 Seat* 14 1 Spacer

5A 2 Disk Spring* 15 1 Handle Nut

6 C/F Bolts 16 1 Stop Bolt

7 1 Thrust Washer* 17 1 Stop Nut

81 Stem 181 Handle

8A 2 Half Split Ring* 19 2 Housing Seal*

9 1 Stem Packing* 20 2 Back-up Seal*

www.jﬂowcontrols.com

sales@jﬂowcontrols.com

J Flow Controls

4665 Interstate Dr.

Cincinna, OH 45246

Toll Free: 866-95-JFLOW (53569)

Local: 513-330-6354

Fax: 513-731-6939

DM 4800 Series MS Ball Valve

Installaon – Maintenance Manual

Document #: IM-DM4800 MS-01

Rev Date: 2010-02-01

Installaon & Maintenance for J Flow DM4800 Series Metal Seated Ball Valve

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