cashco RANGER QCT Instruction manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) IOM-Ranger
02-20
RANGER QCT
ROTARY CONTROL VALVE BODY ASSEMBLY
FLANGED OR FLANGELESS DESIGN
SECTION I
SECTION II
ABBREVIATIONS
ATC-FO – Air-to-Close, Fail Open
ATO-FC – Air-to-Open, Fail Close
CCW – Counter-Clockwise Rotation
CS – Cast Carbon Steel
CW – Clockwise Rotation
CWP – Cold Working Pressure
DIR – Direct Acting
DI – Ductile Iron
IAS – Instrument Air Supply
IOM – Installation, Operation and Maintenance
Manual
LOAD – Positioner Output Air Pressure
REV – Reverse Acting
RF – Raised Face
SIG – Output Signal from Instrument
SST – Cast or Wrought 316 Stainless Steel
V – Vent
I. DESCRIPTION AND SCOPE
This manual covers the body assembly of the Cashco
Ranger QCT. Available sizes include 1", 1-1/2", 2",
3", 4", 6" and 8" (DN25, 40, 50, 80, 100, 150, 200).
Flangeless DI bodies fit 150 and 300 lb. RF flanges.
Flangeless CS and SST bodies, all sizes, fit 150,
300 and 600 lb. RF flanges. Integral flanged CS and
SST bodies, sizes 1" through 3", mate with 150, 300
and 600 lb. RF flanges. Integral flanged CS and SST
bodies, sizes 4", 6" and 8", mate with 150 and 300 lb.
RF Flanges. All sizes of flangeless construction may be
installed between PN40 flanges. Quick Change Trim
(QCT) is furnished as a standard feature and allows
use of several seal retainers and inserts to vary orifice
size, help control cavitation and reduce noise. All trims
use 90° plug rotation. Disassembly, inspection and
reassembly of the trim can be accomplished easily
without disturbing the packing, linkage or positioner
calibration. Trim parts are self-centering.
Either of Cashco's pneumatically actuated actuators,
Model 48 and Model 148, can be mounted to the
Ranger QCT body.
II. REFERENCES
Refer to Technical Bulletin Ranger-TB for complete
technical specifications coupled with either Cashco
Actuator Model 48 or 148.
www.cashco.com/techbulletins/ranger.pdf
Refer to following Installation, Operation & Main-
tenance Manuals (IOM’s) for either actuator and/or
devices that maybe mounted to a Model Range body:
Actuators: www.cashco.com/IOM/48.pdf
www.cashco.com/IOM/148.pdf
Positioners:
P/P: www.cashco.com/techbulletins/73.pdf
P/P: www.cashco.com/techbulletins/9540r.pdf
I/P: www.cashco.com/techbulletins/srd991.pdf
I/P: www.cashco.com/iom/PS2iom.pdf
ISO Registered Company

IOM-Ranger2
SECTION III
FIGURE 1: Typical Control Valve Station FIGURE 2: Line Bolting Clearance
_ MANUAL BYPASS
BLOCK
DRAINDRAIN
CONTROL
VALVE
BLOCK
SIG
LOA
IAS
AIRSET
I/P
PO SIT
V
2. If the pipe reducers, elbows, noise attenuation
devices, etc., are located before and/or after
the valve body, keep these pieces as close
as practical to the valve body.
NOTES: 1. For flangeless design, allow
sufficient clearance upstream from valve body
for line bolt insertion and removal. See Figure
2 and Table 1.
2. Undue piping stress/strain or bending
torques may not be transmitted through the
control valve body. One pipe (inlet or outlet)
should be anchored rigidly for piping that
is “hot” or “cold’” with respect to ambient
temperature; the remaining pipe (inlet or
outlet) should be supported and guided to
ensure unidirectional expansion/contraction.
Properly align prior to installing valve with
required flange bolting.
3. Clean the piping of all foreign debris, including
chips, weld scale, weld splatter, oil, grease,
sand or dirt, prior to installing the control valve.
THIS IS AN ABSOLUTE REQUIREMENT!
4. Field hydrostatic testing the completed piping
system, including the Ranger QCT valve,
to the max allowable CWP indicated on the
valve’s nameplate is acceptable. If hydro test
pressure is to exceed this limit, the Ranger
QCT must be removed before such testing.
Before pressurization, the valve plug must be
rotated out of the seat if of reverse, ATO-FC
action.
WARNING
The valve/actuator unit should not be used as a “step” to
support personnel. Failure to comply may cause leakage
at the flange/valve body joint, especially for flangeless
body design.
III. INSTALLATION
A. Orientation:
1. Preferred orientation when valve is installed
in either a horizontal or vertical pipeline is
with the valve stem horizontal. Valves may
be installed with the stem anywhere between
horizontal or vertical for all sizes.
2. Ranger QCT valve with actuator is not
recommended for installation with the actuator
oriented downwards.
3. In no case is additional weight to be applied
to the actuator subassembly when installed
in any orientation.
B. Piping System:
1. It is recommended that the control valve unit
be installed with a double-block and bypass
as indicated in Figure 1. This arrangement is
necessary when maintenance is to be done
on the valve body. Valve must be removed
from the pipeline to gain access to unit’s
internal trim parts.

IOM-Ranger 3
TABLE 1 – LINE BOLTING REMOVAL CLEARANCE
2. For ATC-FO Direct Action Valves with
Handwheel Assembly:
a. After installation in piping, loosen locking
lever (59) and turn handwheel (58) CCW
to fully open the plug (6).
b. Check travel indicator (16) to confirm
valves full open plug position.
c. Tighten locking lever (59).
NOTE: For shipping and installation purposes
these valves use a handwheel to temporarily
hold the plug in the closed position.
CAUTION
DO NOT INSTALL ANY RANGER QCT VALVE WITH
THE PLUG IN THE OPEN POSITION. The cage and seals
may shift during installation. The resulting misalignment
of plug and seals will negate the Class IV or Class VI
seat leakage capabilities.
C. Plug Position for Installation:
NOTE: All ATC-FO valves are shipped from the
factory in the closed position to ensure alignment
of body trim internals. After installing valve body
in piping system, rotate valve plug to full open
position.
1. All indicated Item Numbers that are with
respect to IOM-48 or IOM148 will be in
parenthesis and underscored; i.e. (20); the
same is true for the positioner parts. All Item
Numbers that are with respect to this IOM-
Ranger are not underscored; i.e. (6).
Body Size Reducer
Size
150# Flgs. 300# Flgs. 600# Flgs.
L1 L2 L1 L2 L1 L2
1" (DN25)
None
8.38
(213)
Min
8.75
(222) Min 8.94 (227) Min
1-1/2"x1" Min
2"x1" Min
2-1/2"x1" 7.38 (187)
1-1/2" (DN40)
None
8.44
(214)
Min
9.88
(251)
Min
10.12
(257)
Min
2"x1-1/2" Min Min Min
2-1/2"x1-1/2" Min Min Min
3"x1-1/2" Min Min Min
4"-1-1/2" 7.44 (198) 8.88 (226) 9.12 (232)
2" (DN50)
None
10.06
(256)
Min
10.13
(257) Min 10.50 (267) Min
2-1/2"x2" Min
3"x2" Min
4"x2" 9.00 (229)
3" (DN80)
None 11.50
(292)
Min 13.44
(341)
Min 13.88
(353)
Min
4"x3" Min Min Min
6"x3" 10.25 (260) 12.19 (310) 12.63 (321)
4" (DN100)
None
12.50
(318)
Min
13.56
(344)
Min
16.00
(406)
Min
6"x4" Min Min Min
8"x4" 11.0 (279) 12.00 (305) 14.50 (368)
10"x4"
6" (DN150)
None
14.81
(376)
Min
16.25
(413)
Min
18.63
(473)
Min
8"x6" Min Min Min
10"x6" Min Min Min
12x6" 12.75 (324) 14.00 (356) 16.56 (421)
14"x6"
8" (DN200)
None
15.50
(394)
Min
18.75
(476)
Min
20.38
(518)
Min
10"x8" Min Min Min
12"x8" Min Min Min
14"x8" 15.50 (394) 16.68
(424) 17.93 (455)
16"x8"

IOM-Ranger4
CAUTION
Do not torque line bolting beyond the limitations of
Table 3. Reference the “Ranger-TB” for temperature
range of Opt-7A alloy steel and Opt-7C SST line bolting.
TABLE 2
Recommended Line Bolting Dimensions
Valve Size Line Flange
ANSI Class
Tie Rod Studs
Dia.-Thd. UNC Qty. Length
1" 150 1/2"-13 4 7.75"
300-600 5/8"-11 4 8.00"
1-1/2" 150 1/2"-13 4 7.75"
300-600 3/4"-10 4 9.00"
2" 150 5/8"-11 4 9.25"
300-600 5/8"-11 8 9.25"
3" 150 5/8"-11 4 10.50"
300-600 3/4"-10 8 12.25"
4"
150 5/8"-11 8 11.50"
300 3/4"-10 8 12.25"
600 7/8"-9 8 14.25"
6"
150 3/4"-10 8 13.75"
300 3/4"-10 10 14.75"
3/4"-10 4 5.50
600 1"-8 10 16.50"
1"-8 4 6.75"
8"
150 3/4"-10 8 15.50"
300 7/8"-9 10 16.50"
7/8"-9 4 6.25"
3. Line Bolting Material must comply with ANSI B16.34
and be compatible with the intended service.
4. Tighten the line bolting evenly and in small
increments to avoid uneven loading of the seal
retainer (3) and seal retainer gasket (9). See Table
3 for minimum and maximum line bolting torques.
CAUTION
Do not allow the body to “cock” between the flanges.
Valve must be centered on the flanges.
D. Body Installation:
The Ranger QCT body can be installed between
ANSI Class 150, 300 or 600 lb. RF or FF flanges
or their ISO equivalent of PN20, 50 or 100. Socket
weld, weld neck or slip on companion flanges
can be used. Face-to-face dimensions are per
ISA 75.08.02.
1. Install valve so the flow direction matches the
arrow on the valve body.
2. For flangeless design alignment, special
bosses cast on the valve body contact the line
bolting and help center the valve in the pipeline.
See Table 2 for Line Bolting Dimensions.
CAUTION
DO NOT USE THE RANGER BODY ASSEMBLY AND
LINE BOLTING TO PULL FLANGE PIPE ENDS INTO
ALIGNMENT. Seal retainer may shift, damaging the seal
retainer gasket allowing leakage between body and seal
retainer. Movement of seal retainer may compromise the
valve's ability to meet stated shut-off leakage rates. Could
also allow leakage between body and flange pipe ends.
WARNING
Do not adjust temporary air supply pressure after cover
plate (20) has been removed. Valve contains parts which
could move during maintenance exposing hand and/or
fingers to a hazardous condition.
TABLE 3
Line Bolting Torques for Flangeless Bodies
Stud Size &
Thread UNC
Max. Torque
Ft-Lb.
Min. Torque
Ft-Lb.
1/2"-13 65 60
5/8"-11 120 100
3/4"-10 200 140
7/8"-9 320 160
1"-8 440 180

IOM-Ranger 5
FIGURE 3:
Insulated Body
Flangeless Design
NOTE: The bonnet
of integrally flanged
bodies should also not
be insulated
SECTION IV
compliance with/to Spec. No. S-1134, the
valve is suitable for oxygen service. This
procedure is limited to bodies of SST material
B. Trim Removal:
Access to the cage assembly with internal trim
pieces may be accomplished without removing the
actuator assembly (AA). Thus, it is not necessary
to remove the packing set (13) or the stem
subassembly (7) to change internal trims. NOTE:
Plug (6) must be in the closed position to remove
the trim.
IV. MAINTENANCE
A. General:
1. Maintenance procedures hereinafter are based
upon removal of the valve/actuator unit from
the piping where installed.
2. Owner should refer to owner’s procedures for
removal, handling and cleaning of nonreusable
parts; i.e. gaskets, suitable solvents, etc.
3. Valves supplied from the factory do not use
any aid to assist in gasket sealing such as oil,
sealant or pipe dope.
4. Valves originally supplied per Opt-55 require
special cleaning procedures. Refer to Cashco
Specification No. S-1134 for details. When in
E. Packing Check:
1. Ensure that packing flange nuts (22) have not
worked loose during shipment.
2. For non-live loaded construction, hand tighten
the nuts (22) enough to stop any leakage. Do
not over tighten.
3. For live loaded construction, if spacer ring
(29) is loose, tighten both nuts (22) equally
until spacer ring (29) no longer “spins freely”
using two fingers. Rotate both nuts (22)
additional 1/2 revolution for correct packing
load. See Figure 9 for correct orientation of
live-loaded packing design.
F. Insulation:
1. Insulate the valve body only. Do not insulate
the integral extension bonnet as this could
result in premature packing failure in low or
high temperature services. See Figure 3.

IOM-Ranger6
1. Position valve on a flat work surface with the
actuator assembly (AA) oriented vertical.
NOTE: If actuator assembly (AA) has been
removed, rotate stem (7) to close plug (6), and
proceed with Steps 4 through 8.
2. If the valve actuator includes a handwheel/
adjustingscrew(58)assembly,usehandwheel/
adjusting screw (58) to remove the closing
torque; i.e. “stem windup”.
a. For ATO-FC valves: Loosen locking
lever/nut (59) with CCW rotation when
viewed from above and rotate handwheel/
adjusting screw (58) CW just enough to
relieve the closing torque, but not enough
to start opening the plug (approximately
1/2-1 handwheel revolution).
b. For ATC-FO valves: Loosen locking lever
(59) with CCW rotation when viewed from
above and turn handwheel (58) CW to
fully close the plug (6) and then back
off enough to relieve the closing torque
by reversing the handwheel/adjusting
screw (58) CCW (approximately 1/2-1
handwheel revolution).
c. Remove machine screws (36) and
cover plate (20). Through opening in
arm housing (4), insert a tool similar to a
screwdriver and apply force to either side
at the lower rod end (9). Rod end (9) will
move easily from side to side when all
closing torque has been relieved.
3. If the valve actuator does not include
handwheel (58) assembly, connect a
temporary air supply with an in-line adjustable
airset regulator with gauge to the actuator top
works. Remove machine screws (36) and
cover plate (20).
a. For ATC-FO Valves: Pressurize actuator
to a level 2-3 psig (0.1-0.2 Barg) under the
upper pressure level of the bench setting
as stated on the name plate (21); i.e. 5-15
psig (.34–1.03 Barg) range, set pressure
at 12-13 psig (.83-.90 Barg). Refer to 2.c.
previous to confirm relief of all closing
torque. Adjust actuator pressure slowly
±1 to 2 psig (±.07–0.2 Barg) to confirm
greatest/easiest movement of lower rod
end (9).
4. Remove the seal retainer screws (18) and
washers (23) and (47)
5. Remove the seal retainer (3) (full orifice,
reduced, anti-cavitation, lo-noise), seal retainer
gasket (9), soft seal (10) (if supplied) and metal
seal (11).
6. Through backside of body (1), place a wooden
hammer handle on the vane on the back side
of the plug (6), or the LN2–LN4 lo-noise insert
(25), and tap lightly to remove cage assembly.
7. Remove bearings (4)( 5) from the cage (2).
(If necessary, pry or tap the bearings loose.)
Rotate plug (6) 135° to 180° from the closed
position and lift plug (6) from the cage (2).
8. Remove abrasion sleeve (26) or LN2–LN4
lo-noise insert, if installed.
9. Depressurize actuator for ATC-FO valves.
C. Trim Reassembly:
Inspect and clean all parts. If any parts are worn,
replace with new parts. If the stem assembly (7)
has been removed, reassemble per Section IV,
Subsection F., then proceed to reassemble the trim.
For sizes 1" - 3", Reorient unit so that the back-end
of the body (1) is directed downwards, and the
front-end is upwards and in a horizontal plane. In
this position gravity will assist in proper alignment of
internals. For 4" - 8" sizes orient body on its side.
NOTES: A. The seal retainer gasket (9) and soft
seal (10) should always be replaced after every
disassembly. Use only original factory replacement
parts.
B. For ATC-FO Valves without handwheel
(58) assembly: Pressurize actuator to levels
indicated per previous Subsection 3.a. to properly
align groove in stem subassembly (7) to mate with
the tongue on the plug (6).
1. Install LN2/4 “lo-noise” insert (25) or “abrasion
sleeve” insert (26) into the body (1) cavity before
inserting the cage/plug subassembly (2)(4)(5)
(6). Ensure that the insert (25)(26) is properly
located within the groove located in the back-
end of the body (1)
NOTE: For proper orientation of LN2, LN3 or LN4
trims, see Figure 6.
WARNING
Do not insert hands/fingers into body (1) or actuator
arm housing (4) openings while actuator is pressurized.

IOM-Ranger 7
5 Short Bearing
4 Long Bearing
2
6
“Tongue” on plug (6) stub shaft,
to engage with stem assembly (7)
“groove”.
“Flat” on cage (2)
“Vane”
on back
side of
plug (6)
Shown with plug (6) in
“closed” position
FIGURE 5
Back-end view of Cage/Plug Subassembly
Back-End
LN1 Trim
FIGURE 6
Lo-Noise Trim – LN2 through LN4
CAUTION
1. If the tongue and groove are not mated together, trim
parts could be damaged.
FIGURE 4: Quick Change Trim Parts
Seal
Gasket
TFE Seal
Ring
Cage
Tongue on
plug shaft Groove on stem
Valve Body
Inconel X-750
Seal Ring
Plug rotated 180° from
closed position for disassembly
Short
Bearing
Seat Retainer
Long Bearing
4. Slip bearings (4)(5) onto the plug (6) stub
shafts.
NOTE: Bearings (4) (5) are not the same length.
The shorter bearing (5) fits the plug (6) stub shaft
that has the tongue end. See Figure 5.
5. Rotate plug (6) to the closed position. Ensure
that the plug (6) is fully pulled into the
mechanical stop (5) on the cage (2). See Figure
7. Ensure that the closing torque is nil; i.e.
actuator assembly (AA) linkage is “loose” or
“slack”.
6. Insert the cage/plug subassembly (2)(4)(5)(6)
into the body (1). On 1-1/2" and 2" sizes with
lo-noise inserts or abrasion sleeve, make sure
these pieces and the cage (2) slip together
on the back of the cage (2). Make sure the
tongue on the plug (6) stub shaft and the
groove in the stem subassembly (7) mate
together. Check by looking in through the
back-end of the body (1) or by adjusting the
supply pressure to the actuator within limits
of bench range as specified on name plate
(21), watching for plug (6) movement as stem
subassembly (7) rotates.
2. If at the body assembly (BA) level, ensure
that the stem subassembly (7) is pulled back
into the bonnet of the body (1) so that the
stem (7) is in contact with the retainer sleeve
subassembly (8).
3. Place plug (6) into cage (2). The orientation
must be such that the short stub shaft of the
plug (6) with the machined tongue extends
through the flat side of the cage (2) toward
the stem (7). The plug (6) must be rotated
135° to 180° open before the plug (6) stub
shafts will slip into the cage's (2) bearing (4)
(5) slots. See figures 4 and 5.

IOM-Ranger8
FIGURE 7
Mechanical Travel Stops - Plug in Closed Position
Front-End View
Mechanical
Stop
Cage (2)
Mechanical
Stops
Cage (2)
Sizes 2" & 4"
(DN50 & 100)
Plug (6)
Plug (6)
FIGURE 8:
Typical Seal Assembly
Sizes 1", 1-1/2", 3", 6" & 8"
(DN25, 40, 80, 150 & 200)
CAUTION
The valve must be isolated from the process, all
pressures must be relieved and the unit removed from
the piping system before attempting disassembly.
9. Install washers (23), Belleville
washers (47) (convex side up) and
cap screws (18) and hand tighten.
Reduced port seal retainers (3) have recesses
machined-in to receive the washers (23,
47). See Figure 17. These ensure that the
elongated port (slot) is properly aligned.
Wrench-tighten the cap screws (18) in 1/2
revolution increments, in an alternating
pattern, until tight.
NOTE: The seal retainer gasket (9) and the soft
seal (10) are not “set” until the valve is placed in
the line and compressed between flanges. If the
seals are “set” by clamping the valve between the
flanges during a seat leakage test, retighten the
cap screws (18) to hold the seal retainer (3) and
seals (9, 10 and 11) firmly in place. Once a soft
seal (10) is “set” by clamping the valve between
flanges, it cannot be removed, reinstalled and
then properly centered to provide Class VI shutoff.
10. On ATO-FC and ATC-FO Valves without
handwheel (58), replace cover plate (20)
and machine screws (36). Depressurize the
actuator for ATC-FO valves and disconnect
temporary air supply.
11. Return to Section III.A. through F. for
installation instructions.
NOTE: All Sizes - Reorient unit so that the back-
end of the body (1) is directed downwards, and
the front-end is upwards and in a horizontal plane
so seals properly align on plug.
7. With plug (6) in the closed position, install the
metal seal (11) with chamfered edge of I.D.
toward the plug (6); a note is “etched” on the
side of the metal seal (11) stating “TOWARD
PLUG”. Place seal retainer gasket (9) against
body (1) face and metal seal (11). Place soft
seal (10) against plug (6) face. See Figure 8
for assembly details.
NOTE: The soft seal (10) is not used with anti-
cavitation trim (3) or with some trim designations.
In reverse flow direction, the soft seal (10) is
ineffective.
8. Carefully set seal retainer (3) into position.
Visually check to see if the soft seal (10) is
centered over the metal seal (11), and that
the plug (6) is closed.
NOTE: To center the seals on the plug (6) face,
hold the seal retainer (3) against the assembled
trim parts with light hand pressure and rotate the
seal retainer (3) back and forth 90°, 3-4 times.
Spin 360° 3-4 revolutions.
D. Stem Removal:

IOM-Ranger 9
Max Wear
Max
Wear
29
28
2
1
2", 3" & 4" RANGERS ONLY
6 Spring Washers
Non-Inverted Retainer
FIGURE 9
Ranger Live-Loaded Packing Design
Initial Setting
Position - TYP
Maximum Wear Position
-Adjustment Required - TYP
Max Wear
0.050"-0.060"
- TYP
Max
Wear
1" & 1-1/2" RANGERS ONLY
8 Spring Washers - Inverted Retainer
i. Pull yoke (12), packing flange (14), packing
follower (15) and follower bushing strip
(16) off over end of stem (7). Replace
packing follower (15) if significantly
corroded. Always replace follower
bushing strip (16) when of standard
construction. (NOTE: When Opt-38HT
high temperature packing is supplied,
the packing follower (15.1) contains a
pressed-in carbon bushing (15.2) that is
not field replaceable and must be supplied
as a packing follower (15) subassembly.)
j. Loosen stem retainer screw (17) by
rotating CCW (viewed from above screw
head) 2-3 revolutions to check for trapped
fluid. After all fluid is vented, remove screw
(17).
k. Rotate stem (7) CW when viewed from
actuator end of stem (7) to close plug (6).
l. Withdraw stem subassembly (7), retainer
sleeve subassembly (8) and packing set
(13) out of body (1).
NOTE: If difficulty is encountered in removing
the stem subassembly (7), use a puller
assembly. See Figure 10. Hold the double nut
with a wrench to prevent rotation of the stem
as this could damage the seals if the trim is
still in the valve body (1). Use the single nut
to jack the stem subassembly (7) out.
1. Remove the actuator assembly (AA) from the
valve body assembly (BA). Refer to Actuator
maintenance manuals IOM-48 or 148.
2. Secure body (1) in a vise with the stem (7)
horizontal to the floor. Place matchmarks
between yoke (12) and body (1) to assist in
final orientation when re-assembled.
3. For live-loaded construction:
a. Loosen both packing flange nuts (22) until
clearance exists between the bottom of
the nut (22) and the retainer (28).
b. Spacer ring (29) should “spin freely”. If
stacked mechanism (27)(28)(29) is not
loose due to corrosion, debris, packed
dirt, etc., tap the spacer ring (29) lightly
while attempting to pry up the spacer ring
(29) bottom with a thin flat tool.
c. Remove both packing flange nuts (22)
only after the live-loaded mechanism (27)
(28)(29) is “free” and loose.
d. Pry up both live-loaded mechanisms (27)
(28)(29) one side at a time. Carefully lift the
mechanism (27)(28)(29) over the packing
stud (21) ensuring that the Belleville spring
washers (27) are not dropped in removal,
preventing a determination of washers'
(27) orientation one-to-the-other. Set
the two mechanisms (27)(28)(29) down
together, side by side.
e. Inspect the retainers (28) for orientation.
Both of the retainers (28) should have
the same orientation. Improper/differing
orientations will cause unbalanced
loading of the packing rings (13). See
Figure 9 for proper orientation.
f. Inspect both spring washer (27) stacks
for proper orientation by carefully lifting
off the spacer ring (29) and retainer (28),
exposing the spring washer (27) stack.
Each stack of spring washers (27) should
be oriented the same. Improper/differing
orientation will cause unbalanced loading
of the packing rings (13). See Figure 9
for proper orientation.
g. Replace all Belleville spring washers
(27) if there are any signs of corrosion.
It is recommended that spring washers
be replaced in full sets. The spacer rings
(29), retainers (28), as well as the packing
studs (21) should be replaced if corroded.
h. Remove yoke (12) bolting by removing
two cap screws (19) on 1", 1-1/2" and 2"
sizes, or two nuts (22) on the 3", 4", 6"
and 8" sizes.

IOM-Ranger10
4. For Non-Live-Loaded Packing Construction:
a. Remove two packing flange stud nuts
(22) and two cap screws (19) on the 1",
1-1/2" and 2" sizes, or four nuts (22) on the
3", 4", 6" and 8" sizes.
b.Pull yoke (12), packing flange (14), packing
follower (15) and follower bushing strip (16) off
over end of stem (7). Replace packing follower
(15) if significantly corroded. Always replace
follower bushing strip (16) when of standard
construction.
c. Proceed with previous steps 3.j. through 3.q.
for stem removal.
E. Stem Reassembly – Trim Retained in Body:
1. Slide retainer sleeve subassembly (8) onto
the stem subassembly (7), with the carbon
bushing (8.2) end against the shoulder of the
stem subassembly (7).
NOTE: For Slurry Trim see Subsection H.
2. Insert the stem/retainer sleeve (7)(8) assembly
into the body (1), aligning the hole in the retainer
sleeve (8) to be directly in line with the threaded
hole in the body (1) bonnet. Align the stem
subassembly (7) so that the plug’s (6) tongue
and the stem's (7) groove will engage.
NOTE: A small "flat" area has been milled on the
stem and for correct engagement this "flat" must
be on the same side as the face of the plug (6).
3. Visually confirm alignment of hole in retainer
sleeve (8.1) with threaded hole in body
(1) bonnet. Place thread sealant Cotronic
Resbond 907, or equal, on stem retainer screw
(17) threads for valves used in non-oxygen
service; thread sealant to be Occidental
Petroleum Corp. Fluorolube GR-362, or
equal, for valves used in oxygen service.
Insert and tighten stem retainer screw (17)
20-25 ft# (27-34 N-M) for 1"– 2" sizes,
80-85 ft# (108-115 N-M) for 3"– 8LF" sizes
and 90 ft# (122 N-M) for 8"HF size.
4. Rotate stem (7) to ensure tongue and groove
engagement with plug (6).
m. Using a suitable solvent acceptable to the owner,
thoroughly clean the valve stem (7) and the
body's (1) stuffing box. Inspect surface finish of
stem subassembly (7) and internal wall finish of
packing box bore at packing (13) area. If deeply
scratched, corroded or pitted, replace with new
parts.
n. It will be desirable to restore the surface of
the body's (1) stuffing box to 16 micro-inch Ra
finish; metal removal should not exceed 0.001
inch material.
o. It will be desirable to restore the surface of the
stem's (7) critical area to 6–8 micro-inch Ra
finish or better, metal removal should not exceed
0.001 inch material. Minimum stem OD should
not be less than indicated in Table 4.
p. Remove retainer sleeve subassembly (8) from
stem subassembly (7). Examine carbon bushing
insert of retainer sleeve subassembly (8) for
damage or signs of wear. Replace retainer
sleeve subassembly (8) if worn more than 0.005
inch (0.13 mm). See Figure 12 for indicated
dimension “X”.
q. Examine packing studs (21) and nuts (22).
Replace if signs of corrosion are present.
TABLE 4 - STEM O.D.
Body Size Minimum Stem O.D.
1", 1-1/2" & 2"
(DN25, 40 & 50) .620
3" & 4"
(DN80, 100) .995
6" & 8"
(DN150, 200) .995
DIMENSIONS
Valve A B C D E F G
Size (Pipe Size) (O.D.) (I.D.) (Thd Rod)
1", 1-1/2," 3/4" 7-13/16" 1-1/4" 5/16" 3/16" 1/4"-28 4"
2"
3", 4" 1-1/2" 11-13/16" 2-1/8" 7/16" 1/4" 3/8"-24 4-1/2"
6", 8" 2-1/2" 9-3/16" 3-1/8" 7/16" 1/4" 3/8"-24 4-1/2"
FIGURE 10: Stem Puller
CAUTION
Do not hammer on end of stem. Potential exists to
cause damage to the tongue and groove connection
or to the seals.
CAUTION
The tongue and groove connection between the stem
subassembly (7) and the plug (6) can cause mechanical
damage or disengagement if the carbon bushing insert
is worn.