Bray Flow-Tek FTG Series User manual

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation Operation and Maintenance Manual
BRAY.COM THE HIGH PERFORMANCE COMPANY

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
2 of 11©  BRAY INTERNATIONAL INC ALL RIGHTS RESERVED BRAYCOM The Information
contained herein shall not be copied transferred conveyed or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International Inc
CONTENTS
 DEFINITION OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 OPERATION AND TRAVEL STOP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
 GEAR LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
3 of 11©  BRAY INTERNATIONAL INC ALL RIGHTS RESERVED BRAYCOM The Information
contained herein shall not be copied transferred conveyed or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International Inc
 DEFINITION OF TERMS
All information within this manual is relevant to the safe operation
and proper care of your FTG Series Manual Gear Operator
Please understand the following examples of information used
throughout this manual
DANGER
Indicates a potentially hazardous situation which if not avoided
will result in death or serious injury
WARNING
Indicates a potentially hazardous situation which if not avoided
could result in death or serious injury
CAUTION
Indicates a potentially hazardous situation which if not avoided
could result in minor or moderate injury
NOTICE
Used without the safety alert symbol indicates a potential
situation which if not avoided may result in an undesirable result
or state including property damage
READ AND FOLLOW THESE INSTRUCTIONS CAREFULLY
SAVE THIS MANUAL FOR FUTURE USE

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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violate its proprietary nature without the express written permission of Bray International Inc
 INTRODUCTION
Flow-Tek’s FTG Series Manual Gear Operators were designed to
handle the toughest applications and provide years of trouble-
free service and reliability
The FTG Series gear operators feature a ductile iron housing
aluminum bronze gear segment and one-piece steel worm gear
input shaft with tapered roller bearings on both ends
Adjustable travel stops provide precise adjustment in both open
and closed positions
Weather proof seal caps ensure travel stop adjustment is
operational through harsh environmental conditions
The gears are self-locking and able to hold any position
necessary The gear housings are sealed and weatherproof to
fully isolate internal parts from atmospheric conditions
External locking devices readily avaiable
Features include a readily accessible hand-wheel position
indicator ISO  mounting pattern and mechanical travel
stops which permit field adjustment of valve position as required
WARNING
Gear operator handwheel is attached to input shaft with pin The
gear operator with or without valve should never be lifted by
handwheel as that can lead to mechanical damage of the pin
input shaft housing and or worm gear

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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 INSTALLATION
For direct mount skip bracket coupler installation and proceed
with mounting studs installation
Insert mounting coupler into the gear and manually operate the
gear operator until coupler machined area is in line with valve
stem
Remove coupler from the gear
Install mounting bracket as required using valve mounting plate
and supplied fasteners It is recommended to use a small amount
of Anti-seize on the threads during assembly Fasten bracket
loosely
Place mounting coupler onto the valve stem It is recommended
that a small amount of lubricant or Anti-seize is applied to the
stem adaptor at both connections – to the valve stem and to the
gear operator
Install the mounting studs into the gear unit mounting holes
Carefully lower the gear unit over valve stem or stem adaptor
Make sure that the mounting studs are aligned with the holes
on the valve top mounting plate or with the top holes on the
bracket
WARNING
Do not place fingers or hand between gear operator and
mounting plate during installation as this is a pinch point
Tighten both gear nuts and bracket fasteners Ensure that the
gear is centrally mounted on the valve stemcoupler

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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violate its proprietary nature without the express written permission of Bray International Inc
 OPERATION AND TRAVEL STOP ADJUSTMENT
To close the valve rotate the gear handwheel clockwise (right)
To open the valve rotate the gear handwheel counterclockwise
(left) The position indicator bolted to the rotating gear indicates
the valve position and moves as handwheel is turned
NOTICE
Position Indicator of the gear is for reference It is not calibrated
to show exact position
Image  - Indicator Plate
Image  shows the position indicator plate A clockwise rotation
(Right) of the gear input shaft will move the indicator arrow
clockwise towards the “SHUT” marking and closed position stop
(position shown in Image )
A counterclockwise rotation (Left) of the gear input shaft will
move the indicator arrow counterclockwise towards the “OPEN”
marking and open position stop
Position
Indicator

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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Image  - Heavy Hex Counter Nuts
Image  - Buna Weather Seal Caps
The gear stops consist of hex socket adjustment studs and heavy
hex counter nuts shown in Image  They are protected by Buna
weather seal caps shown in Image 
Gears mounted at the factory are shipped fully set and no
adjustment is needed If the gear has been removed replaced or
the integrity of the stops have been aected both stops shall be
re-adjusted
Tools needed to adjust gear stops
 Adjustable or combination wrench
 Allen hex wrench set
 Setting the stops with valve mounted in line
Once gear is mounted remove seal caps (Image ) and position
indicator (Image )
For a gear mounted with the valve in the closed position
 Loosen counter nut while holding the adjustment stop stud
with Allen wrench (Image )
 Loosen adjustment stop stud by turning counterclockwise
Hex Socket
Adjustment
Stud
Seal
Cap
Hex
Counter
Nut

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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violate its proprietary nature without the express written permission of Bray International Inc
Image  - Gear Stem Nut
 Remove the indicator plate by removing the screws that are
securing it to the top of the gear Check position of gear stem
nut (Image ) The stem nut is machined with two concentric
squares with a  degree oset angle
 If flats of the stem nut squares are not parrallelperpendicular
to the valve bore adjust the position by turning handheel as
needed
 Once the position of the stem nut is set drive the adjustment
stop stud by hand until feeling resistance
 While holding adjustment stop stud with Allen wrench in
position tighten the counter nut Do not allow the adjustment
stop stud to move
 Using the handwheel turn the valve to be - degrees
unseated and close again The gear should stop at set position
where the stem nut squares are parrallelperpendicular to flow
bore If not repeat adjustment steps
 Repeat these steps for setting the stops for the fully open
position
 Setting stops with valve on work bench
 Start setting gear stops in the fully open position
 Loosen counter nut while holding the adjustment stop stud
with Allen wrench (Image )
 Loosen the adjustment stop stud by turning counterclockwise
 Fully open valve Check position of the ball by looking through
the end of the valve bore If not fully open adjust position by
turning handwheel accordingly
 Once fully open position is set tighten the adjustment stop
stud by hand until feeling resistance
 While holding the adjustment stop stud with Allen wrench
in position tighten the counter hex nut Do not allow the
adjustment stop stud to move

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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contained herein shall not be copied transferred conveyed or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International Inc
 Using handwheel turn the valve to be - degrees unseated
and then open again The gear should stop at set position
where ball bore is aligned with the seat inner diameter and
valve bore
 For fully closed position loosen the counter nut while holding
the adjustment stop stud with Allen wrench (Image )
 Loosen the adjustment stop stud by turning counterclockwise
 Start closing the valve by rotating handwheel clockwise Stop
when the machined square of the gear stem nut rotates 
degrees and mark the position
 Tighten the adjustment stop stud by hand until feeling
resistance
 While holding the adjustment stop stud with Allen wrench
in position tighten the counter hex nut Do not allow the
adjustment stop stud to move
 Using the handwheel turn valve to be - degrees unseated
and close again The gear should stop at the set position
where marked
 After both stops are set replace the seal caps and position
indicator

FLOW-TEK FTG SERIES
MANUAL GEAR OPERATOR
Installation, Operation, and Maintenance Manual
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contained herein shall not be copied transferred conveyed or displayed in any manner that would
violate its proprietary nature without the express written permission of Bray International Inc
 GEAR LUBRICATION
FTG gears come from the factory with lubricant already applied
Proper lubrication is necessary to ensure smooth operation and
long life of the unit These instructions are to be used during
original assembly and prior to reassembly following service or
scheduled maintenance
Worm and worm gear - lubricate both hubs and shoulders apply
grease to the worm and worm gear teeth in such a way that it
is carried through the meshing of the gears After applying the
grease rotate the worm at least two () complete cycles (one
cycle being from closed-open-closed or open-closed-open) After
cycling inspect and re-apply grease as needed
Apply grease liberally to all mating surfaces O-rings gaskets
and shafts
Cover inside of gear box with thin layer of grease as to prevent
rust build up caused by condensation
NOTICE
Gear operators intended for marine service high-humidity or
buried service and so specified on the Purchase Order or Sales
Order must have housing(s) filled with grease and properly
sealed
The lubricant must be a high-pressure or extreme pressure
petroleum grease with a lithium based thickener which meets the
NLGI Grade  The grease must exhibit a high degree of tackiness
which enhances its ability to cling to the intended surfaces
The grease should meet the following specifications as a
minimum Any deviation below these specifications must be
approved by Flow-Tek Engineering
Typical Properties ASTM
Test Method Result
NLGIGrade Number – 
Soap Type – Lithium
Color – Brown
Mineral Oil Viscosity SUS @ F [C] D 
Penetration (Worked  Strokes) D 
Dropping Point (Maximum Temperature) D F [C]
Oil Separation D 
Rust Preventative Test D Pass
Timken EP Test D  lbs [ kg]
Wheel Bearing Test
( mph [ rpm] F [C] leakage) D  gms
Oxidation Stability  hrs psi drop D 
Water Washout Test ( loss @ F [C] typ) D 
1National Lubricating Grease Institute

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