Emerson Fisher D4 User manual

www.Fisher.com
D103042X012
Design D4 Control Valve Assembly
Contents
Introduction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scope of Manual 1. . . . . . . . . . . . . . . . . . . . . . . . .
Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring Adjustment 5. . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Plug and Seat Ring 6. . . . . . . . . . . . . . . . . .
Valve Packing 7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actuator 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Ordering 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Kits 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts List 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
Scope of Manual
This instruction manual provides installation,
maintenance, and parts information for the Design
D4 control valve.
No person may install, operate, or maintain a Design
D4 control valve without first Dbeing fully trained
and qualified in valve, actuator, and accessory
installation, operation, and maintenance, and D
carefully reading and understanding the contents of
this manual. If you have any questions about these
instructions, contact your Fisherrsales office before
proceeding.
Note
Neither Emersonr, Emerson Process
Management, Fisher, nor any of their
affiliated entities assumes
responsibility for the selection, use
and maintenance of any product.
Responsibility for the selection, use,
and maintenance of any product
remains with the purchaser and
end-user.
Figure 1. Design D4 Control Valve
W8531/IL
Description
The Design D4 control valve is a compact, rugged
valve designed primarily for high-pressure throttling
applications. This valve is ideal for use on pressure
and flow control applications within the oil and gas
production industry. The Design D4 valve also
makes an excellent dump valve for high-pressure
separators and scrubbers.
Specifications
Table 1 lists specifications for the Design D4 control
valve. Some of the specifications for a given control
valve as it originally comes from the factory are
stamped on a nameplate located on the actuator
spring barrel.
Instruction Manual
Form 5755
September 2005 D4 Valve

D4 Valve
Instruction Manual
Form 5755
September 2005
2
Table 1. Specifications
Available Configurations
Spring-to-Close
Spring-to-Open
Valve Body Sizes and End Connection Styles(1)
See table 2
Maximum Inlet Pressures and Temperatures(1)
If the valve nameplate shows an ASME
pressure-temperature class, maximum inlet
pressure and temperature is consistent with the
applicable class per ASME B16.34. If the
nameplate does not show an ASME class, it will
show a maximum cold working pressure at 38_C
(100_F) (for example, 248 bar [3600 psi])
Maximum Pressure Drops(1)
See tables 3, 4, 5, and 6
Input Signal to Actuator
See tables 3, 4, 5, and 6
Actuator Maximum Casing Pressure(1)
3.4 bar (50 psig)
Shutoff Classification per ANSI/FCI 70-2
and IEC 60534-4
Class IV
Material Temperature Capabilities(1)
Actuator Assembly: –40 to 93°C (–40 to 200°F)
Valve Body Assembly:
Standard Bonnet O-Ring: –46 to 149°C (–50 to
300°F)
Optional Fluoroelastomer Bonnet O-Ring: –23 to
204°C (–10 to 400°F)
Flow Characteristic
Equal percentage
Flow Direction
Flow up only
Port Diameters
See table 2
Valve Plug Travel
19 mm (0.75 inch)
Valve Plug Style
Micro-Formtvalve plug
Actuator Diaphragm Effective Area
452 cm2(69 inches2)
Actuator Pressure Connection Size
1/4 inch NPT female
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.
Table 2. Valve Sizes and Connection Styles
VALVE
SIZE
PORT
DIAMETER
SCREWED RAISED FACE (RF) FLANGED RING TYPE JOINT
(RTJ) FLANGED
SIZE,
INCHES
DIAMETER,
(INCHES) 3600 psi Class 150 Class 300 Class 600 Class 900
and 1500 Class 600 Class 900 and 1500
10.25, 0.375,
0.5, 0.75 X X X X X X X
20.25, 0.375, 0.5
0.75, 1, 1.25 X X X X X X X
X = Available construction.

D4 Valve
Instruction Manual
Form 5755
September 2005
3
Table 3. Maximum Shutoff Pressure Drops(1) for Design D4 Control Valves (Spring-to-Close)
When Used with Typical Control Instrumentation(2)
INPUT SIGNAL TO
ACTUATOR
0 to 1.2 Bar
(0 to 18 Psig)
0 to 1.4 Bar
(0 to 20 Psig)
0 to 2.0 Bar
(0 to 30 Psig)
0 to 2.3 Bar
(0 to 33 Psig)
0 to 2.4 Bar
(0 to 35 Psig)
0 to 3.4 Bar
(0 to 50 Psig)
SPRING Light Rate Heavy Rate
INITIAL SPRING
SETTING
0.77 Bar
(11.2 Psig)
0.77 Bar
(11.2 Psig)
0.85 Bar
(12.4 Psig)
1.05 Bar
(15.3 Psig)
1.18 Bar
(17.1 Psig)
1.18 Bar
(17.1 Psig)
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
0.25
0.375
0.5
0.75
1
1.25
259(3)
259(3)
191
80
42
25
3750(3)
3750(3)
2765
1160
610
365
259(3)
259(3)
191
80
42
25
3750(3)
3750(3)
2765
1160
610
365
259
259
219
92
49
30
3750
3750
3180
1340
715
430
259
259
259
123
67
41
3750
3750
3750
1785
965
590
259
259
259
143
78
48
3750
3750
3750
2080
1130
700
259
259
259
143
78
48
3750
3750
3750
2080
1130
700
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.
2. For example, use the column marked 0-1.4 bar (0-20 psig) for a 0.21-1.0 bar (3-15 psig) pneumatic controller with 1.4 bar (20 psig) supply pressure.
3. For applications with downstream pressure in excess of 196 bar (2845 psig), use 196 bar (2845 psig) for Maximum Shutoff Pressure.
Table 4. Maximum Shutoff Pressure Drops(1) for Design D4 Control Valves (Spring-to-Close)
When Used with Instrumentation with Restricted Output Range(2)
INPUT SIGNAL TO
ACTUATOR
0.2 to 1.0 Bar
(3 to 15 Psig)
0.4 to 2.0 Bar
(6 to 30 Psig)
SPRING Light Rate Heavy Rate
INITIAL SPRING
SETTING
0.67 Bar
(9.7 Psig)
0.97 Bar
(14.0 Psig)
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
0.25
0.375
0.5
0.75
1
1.25
259(3)
152(3)
80
31
14
7.6
3750(3)
2205(3)
1160
445
210
110
259(4)
210(4)
113
45
23
13
3750(4)
3045(4)
1635
655
330
185
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.
2. For example, an Electro-Pneumatic Transducer calibrated for 0.21-1.0 bar (3-15 psig) output pressure.
3. For applications with downstream pressure in excess of 85 bar (1240 psig), use 85 bar (1240 psig) for Maximum Shutoff Pressure.
4. For applications with downstream pressure in excess of 118 bar (1715 psig), use 118 bar (1715 psig) for Maximum Shutoff Pressure.
Installation
WARNING
Always wear protective gloves,
clothing, and eyewear when
performing any installation operations
to avoid personal injury.
To avoid personal injury or property
damage caused by bursting of
pressure-retaining parts or by
uncontrolled process fluid, be certain
the service conditions do not exceed
the limits shown on the valve
nameplate and in tables 1, 3, 4, 5, and
6. Use pressure-relieving devices
required by government or accepted
industry codes and good engineering
practices.
Check with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.
If installing into an existing
application, also refer to the WARNING
at the beginning of the Maintenance
section in this instruction manual.

D4 Valve
Instruction Manual
Form 5755
September 2005
4
Table 5. Maximum Shutoff Pressure Drops(1) for Design D4 Control Valves (Spring-to-Open)
When Used with Typical Control Instrumentation(2)
INPUT SIGNAL TO
ACTUATOR
0 to 1.2 Bar
(0 to 18 Psig)
0 to 1.4 Bar
(0 to 20 Psig)
0 to 2.0 Bar
(0 to 30 Psig)
0 to 2.3 Bar
(0 to 33 Psig)
0 to 2.4 Bar
(0 to 35 Psig)
0 to 3.4 Bar
(0 to 50 Psig)
SPRING Light Rate Heavy Rate
INITIAL SPRING
SETTING
0.23 Bar
(3.4 Psig)
0.23 Bar
(3.4 Psig)
0.28 Bar
(4.0 Psig)
0.28 Bar
(4.0 Psig)
0.28 Bar
(4.0 Psig)
0.28 Bar
(4.0 Psig)
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
0.25
0.375
0.5
0.75
1
1.25
259(3)
259(3)
187
78
41
24
3750(3)
3750(3)
2715
1135
600
355
259(3)
259(3)
233
99
53
32
3750(3)
3750(3)
3380
1430
765
465
259
259
259
147
80
49
3750
3750
3750
2130
1160
715
259
259
259
178
97
60
3750
3750
3750
2575
1410
875
259
259
259
198
109
68
3750
3750
3750
2875
1575
985
259
259
259
259
195
123
3750
3750
3750
3750
2830
1785
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.
2. For example, use the column marked 0-1.4 bar (0-20 psig) for a 0.21-1.0 bar (3-15 psig) pneumatic controller with 1.4 bar (20 psig) supply pressure.
3. For applications with downstream pressure in excess of 190 bar (2760 psig), use 190 bar (2760 psig) for Maximum Shutoff Pressure.
Table 6. Maximum Shutoff Pressure Drops(1) for Design D4 Control Valves (Spring-to-Open)
When Used with Instrumentation with Restricted Output Range(2)
INPUT SIGNAL TO
ACTUATOR
0.2 to 1.0 Bar
(3 to 15 Psig)
0.4 to 2.0 Bar
(6 to 30 Psig)
SPRING Light Rate Heavy Rate
INITIAL SPRING
SETTING
0.43 Bar
(6.2 Psig)
0.69 Bar
(10.0 Psig)
PORT DIAMETER Maximum Pressure Drop
mm Inches Bar Psi Bar Psi
6.4
9.5
12.7
19.1
25.4
31.8
0.25
0.375
0.5
0.75
1
1.25
226(3)
91(3)
46
15
- - -
- - -
3275(3)
1315(3)
660
220
- - -
- - -
259(4)
259(4)
196
82
43
26
3750(4)
3750(4)
2845
1195
630
380
1. The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded.
2. For example, an Electro-Pneumatic Transducer calibrated for 0.21-1.0 bar (3-15 psig) output pressure.
3. For applications with downstream pressure in excess of 51 bar (740 psig), use 51 bar (740 psig) for Maximum Shutoff Pressure.
4. For applications with downstream pressure in excess of 202 bar (2925 psig), use 202 bar (2925 psig) for Maximum Shutoff Pressure.
CAUTION
When ordered, the valve configuration
and construction materials were
selected to meet particular pressure,
temperature, pressure drop, and
controlled fluid conditions.
Responsibility for the safety of
process media and compatibility of
valve materials with process media
rests solely with the purchaser and
end-user. Since some body/trim
material combinations are limited in
their pressure drop and temperature
ranges, do not apply any other
conditions to the valve without first
contacting your Fisher sales office.
To avoid product damage, inspect the
valve before installation for any
damage or any foreign material that
may have collected in the valve body.
Also remove any pipe scale, welding
slag, or other foreign material from the
pipeline.
1. Before installing the control valve assembly,
inspect it for any damage and for any foreign
material that may have collected in the valve body.
2. Remove any pipe scale, welding slag, and other
foreign material from the pipeline.
3. The control valve can be installed in any position,
but normally the actuator is vertical above the valve.
Install the valve so the flow direction arrow on the
side of the valve indicates the direction of the
process flow.
4. Install the valve following local and national
piping codes when they apply to the application. For
screwed connections, treat the male pipe threads
with a good grade pipe compound. For flanged

D4 Valve
Instruction Manual
Form 5755
September 2005
5
valves, use suitable gaskets between valve and
pipeline flanges.
5. If continuous operation is required during
maintenance and inspection, install a conventional
three-valve bypass around the valve.
6. Connect loading pressure for the Spring-to-Open
configuration to the 1/4-18 NPT connection in the
upper casing assembly (key 23) as shown in
figure 4. The Spring-to-Close configuration loading
pressure connection is in the lower casing assembly
(key 39) as shown in figure 3.
Spring Adjustment
The spring has a fixed pressure span over which
loading pressure will stroke the valve. Adjustment of
the spring compression shifts the span so that more
or less loading pressure is required to start travel.
Since the span does not change, there will be a
corresponding increase or decrease in the pressure
requirements at the end of the valve stroke.
In order to maximize shutoff pressure drop values,
the actuator spring must be accurately adjusted for
each Input Signal Pressure Range. If the actuator
has been disassembled or pressure conditions have
changed, the spring may require adjustment. Refer
to tables 2 and 3 to determine the Initial Spring Set
values based on the Input Signal range that is
available to the actuator. These values include
packing friction.
Spring-to-Close
Refer to figure 3.
1. Loosen the adjusting screw nut (key 44).
2. Turn the adjusting screw (key 31) clockwise to
compress the spring or counterclockwise to
decrease spring compression.
3. After adjustment, tighten the adjusting screw nut
(key 44).
Spring-to-Open
Refer to figure 4.
1. Unscrew the spring case assembly (key 27).
2. Turn the adjusting stem nut (key 44) clockwise to
compress the spring or counterclockwise to
decrease spring compression.
3. After adjustment, replace the spring case
assembly (key 27).
Maintenance
Refer to figure 3.
Valve parts are subject to normal wear and must be
inspected and replaced as necessary. The
frequency of inspection and maintenance depends
on the severity of the service conditions.
WARNING
Avoid personal injury from sudden
release of process pressure or
bursting of parts. Before performing
any maintenance operations:
DAlways wear protective gloves,
clothing, and eyewear when
performing any maintenance
operations to avoid personal injury.
DDisconnect any operating lines
providing air pressure, electric power,
or a control signal to the actuator. Be
sure the actuator cannot suddenly
open or close the valve.
DUse bypass valves or completely
shut off the process to isolate the
valve from process pressure. Relieve
process pressure on both sides of the
valve. Drain the process media from
both sides of the valve.
DVent the power actuator loading
pressure and relieve any actuator
spring precompression.
DUse lock-out procedures to be
sure that the above measures stay in
effect while you work on the
equipment.
DThe valve packing box may
contain process fluids that are
pressurized, even when the valve has
been removed from the pipeline.
Process fluids may spray out under
pressure when removing the packing
hardware or packing rings.
DCheck with your process or safety
engineer for any additional measures
that must be taken to protect against
process media.

D4 Valve
Instruction Manual
Form 5755
September 2005
6
Valve Plug and Seat Ring
The Design D4 control valve is designed to allow
easy access to the valve plug and seat ring without
disturbing the packing. Refer to other sections of this
instruction manual if additional maintenance is
required.
Disassembly
1. Remove the loading pressure tubing and any
accessories that may hamper disassembly.
2. Break the hammer nut (key 6) loose with a
hammer. Continue turning the hammer nut by using
a hammer or a large adjustable wrench, tightened
around one ear of the hammer nut. If the bonnet is
stuck on the valve, continue to unscrew the hammer
nut. The hammer nut will contact the spring pins
(key 7) and will force the bonnet out of the valve.
Carefully lift the actuator, bonnet, and valve plug
assembly from the valve body.
Note
The spring pins must always be in
place during valve operation. They
provide a safeguard against injury
when the unit is being disassembled.
3. Use a socket wrench to loosen the seat ring
(key 3).
4. Remove the seat ring (key 3) and seat ring
gasket (key 9) from the valve body.
5. Inspect parts for wear or damage that would
prevent proper operation of the valve body. Carefully
clean the seat ring gasket surfaces and seat ring
threads.
CAUTION
Be careful to avoid damaging the
seating surface on the valve plug or
seat ring as damage in these areas will
allow excessive leakage at shutoff.
Avoid damaging the highly polished
valve stem surface. A damaged valve
stem could cut the packing and allow
process fluid to leak to the
atmosphere.
6. For spring-to-close only: To remove the valve
plug (key 2), drive out the groove pin (key 4) and
unscrew the valve plug from the stem (key 47). If the
groove pin (key 4) is not exposed, verify that
downward movement of the stem is not restricted by
instrument linkages attached to the stem (key 47).
Table 7. Torque for Seat Ring (Key 3)
VALVE SIZE RECOMMENDED TORQUE
mm Inches NSm LbfSft
25.4 1 407 300
50.8 2 698 515
If the valve plug cannot be easily unscrewed from
the stem, use a punch to keep the stem from turning
as the plug is removed.
7. For spring-to-open only: To remove the valve
plug (key 2), first remove the spring case assembly
(key 27). Remove the adjustment screw nut
(key 44), the upper spring seat (key 29), and the
spring (key 30). Push the adjustment stem (key 31)
fully downward until the diaphragm plate (key 40)
contacts the cap screws (key 38), exposing the
groove pin (key 4) in the plug. If the groove pin
(key 4) is not exposed, verify that downward
movement of the stem is not restricted by instrument
linkages attached to the stem (key 47). Drive out the
groove pin (key 4) and unscrew the valve plug from
the stem (key 47).
If the valve plug cannot be easily unscrewed from
the stem, use a punch to keep the stem from turning
as the plug is removed.
Assembly
1. Make sure the bonnet O-ring (key 8) is on the
bonnet and lubricated with lithium grease or
equivalent (key 49).
2. Install the plug (key 2) on the stem (key 47) and
insert a new groove pin (key 4).
3. Thoroughly clean the seat ring and bonnet
threads in the valve body (key 1). Also clean the
valve body seat ring gasket surfaces.
4. Apply anti-seize lubricant or equivalent (key 54)
to the threads of the seat ring (key 3), and its mating
threads in the valve body.
5. Apply anti-seize lubricant or equivalent (key 54)
to the seat ring gasket (key 9) and install into the
valve body.
6. Screw the seat ring into the valve body. Use a
socket wrench to tighten the seat ring to the torque
values shown in table 7. Remove all excess lubricant
after tightening.
7. Lubricate (key 54) the threads on the valve body
and hammer nut and the contact surfaces of the
bonnet and hammer nut flange. Install the bonnet
and actuator assembly with pinned valve plug onto
the valve body. Tighten the hammer nut using an

D4 Valve
Instruction Manual
Form 5755
September 2005
7
Figure 2. Design D4 Belleville Spring Procedure
BELLEVILLE SPRINGS REASONABLY
TIGHT TO SEAT THE PACKING BELLEVILLE SPRINGS FINGER TIGHT, THEN
TIGHTEN 5/6 TURN (5 FLATS ON THE RETAINER)
E0862
adjustable wrench until the nut stops turning. A few
hammer blows will be required to ensure that the
assembly is tight.
8. See the actuator assembly and spring adjustment
sections of this manual.
Valve Packing
WARNING
Observe the warning at the start of the
Maintenance section.
The valve stem packing can only be accessed from
within the valve body. If packing maintenance is
required, first disassemble per steps 1, 2, and 6 or 7
in the Valve Plug and Seat Ring Disassembly
section of this document.
Disassembly
1. Loosen the packing retainer locknut (key 22) with
a spanner wrench or with a punch and hammer.
2. Unscrew the packing retainer (key 10) from the
bonnet (key 5).
3. Remove the three Belleville springs (key 11),
packing spacer (key 14), packing (key 13), and two
anti-extrusion rings (key 12) from the bonnet, using a
formed wire hook.
4. Clean and inspect the packing box wall to ensure
that the packing surfaces are not damaged. If the
surface condition is damaged, and cannot be
improved by light sanding, replace the bonnet by
contacting your Fisher sales office.
5. Inspect the valve stem for scratches or wear, and
valve plug for wear or damage. Replace if
necessary.
Assembly
Refer to figures 2 and 3.
1. Install new packing and Belleville springs
according to the packing arrangement shown in
figure 2.
2. Apply a light film of lubricant (key 54) to the
threads of the packing retainer (key 10).
3. Install the packing retainer into the bonnet and
tighten until the Belleville springs (key 11) are
reasonably tight to fully seat the packing and
anti-extrusion rings.
4. Completely loosen the packing retainer to relieve
all Belleville spring compression.
5. Retighten the packing retainer by hand until the
packing retainer firmly contacts the Belleville
springs.
6. Tighten the packing retainer clockwise 5/6 turn
(5 flats on the retainer).
7. Lock the packing retainer (key 10) solidly in place
by tightening the packing retainer locknut (key 22)
using a spanner wrench, or a hammer with a punch
or chisel.

D4 Valve
Instruction Manual
Form 5755
September 2005
8
Actuator (Spring-to-Close)
WARNING
Observe the warning at the start of the
Maintenance section.
Refer to figure 3.
Before disassembling the actuator, disassemble the
valve plug, seat ring, and packing according to
instructions in this manual.
Disassembly
1. Loosen the adjusting screw nut (key 44) and turn
the adjusting screw (key 31) counterclockwise to
remove all spring compression.
2. Unscrew the casing cap screws and hex nuts
(keys 45 and 46), and remove the upper casing
assembly (key 23) from the lower casing (key 39).
3. Remove the spring seat (key 29) and actuator
spring (key 30).
4. Lift out the diaphragm, diaphragm plate, and
stem assembly. Remove the travel indicator (key 32)
when the bottom of the stem enters the yoke
window.
5. To replace the diaphragm (key 15), separate the
diaphragm assembly by using a wrench on the hex
nuts (key 42) to unscrew the assembly.
6. Separate the parts—diaphragm washer, actuator
O-ring (keys 41 and 25), diaphragm, and diaphragm
plate, (keys 15 and 40).
7. Inspect the diaphragm and the actuator O-ring for
damage or deterioration, and replace if necessary. If
the diaphragm is replaced, a new O-ring should also
be installed.
8. Inspect the stem O-ring (key 19) and bonnet
bushing (key 20); replace if necessary. To inspect
the casing O-ring (key 18), remove the cap screws
(key 38) and lift off the lower casing (key 39).
Replace the O-ring if necessary.
9. If the hammer nut needs to be removed from the
bonnet, the spring pins (key 7) can be removed with
locking pliers.
Assembly
1. Before starting assembly, make sure all parts are
clean and in good condition. There should be no
burrs or sharp edges on any threads or surfaces that
might cut or damage an O-ring, bushing, the
packing, or the diaphragm. When replacing O-rings
and bushings, be sure the O-ring or bushing groove
is clean and undamaged. Using a general purpose
lubricant (key 49), lubricate all bushings and O-rings
and the threads of parts that have to pass through
the bushings and O-rings.
CAUTION
The threads on factory-produced valve
stems have been specially machined
to avoid O-ring, bushing, or packing
damage during trim maintenance. Use
of other than a factory-produced valve
stem may result in early stem O-ring,
bushing, and packing failure.
Note
Do not lubricate cap screws (key 38)
before inserting them in the following
procedure.
2. Place the hammer nut and spring pins on the
bonnet, if removed. Install the casing O-ring
(key 18), the stem O-ring (key 19), and the bonnet
bushing (key 20). Position the lower casing (key 39)
on the bonnet. Insert the nonlubricated cap screws
(key 38), and torque to 49 NSm (36 lbfSft).
Note
Spring pins must always be in place
during valve operation, acting as a
safeguard against injury when the unit
is being disassembled.
3. Assemble the diaphragm plate assembly. Place
the patterned side of the diaphragm (key 15) against
the diaphragm plate (key 40). Be sure to turn the
diaphragm washer (key 41) so that the side that is
beveled on the inside diameter is against the O-ring
(key 25). Also, make sure that it is assembled for
installation with the diaphragm on the loading
pressure side and the lockwasher (key 43) and lower
spring seat (key 28) are on the spring side.
4. Fasten the diaphragm and diaphragm plate
assembly on the stem with hex nuts (key 42). Place
the diaphragm and diaphragm plate, and stem
assembly into the lower casing and bonnet. Install
the travel indicator (key 32) on the stem as the
bottom of the stem enters the yoke window.

D4 Valve
Instruction Manual
Form 5755
September 2005
9
CAUTION
Over-tightening the diaphragm casing
cap screws and nuts (keys 45 and 46)
can damage the diaphragm. Do not
exceed 27 NSm (20 lbfSft) torque.
5. Replace the spring (key 30) on the diaphragm
plate (key 40). Replace the upper spring seat
(key 29). Position the upper casing (key 23) on the
lower casing (key 39). Insert the cap screws (key 45)
and tighten the hex nuts (key 46). Torque the casing
cap screws evenly to 27 NSm (20 lbfSft) using a
crisscross pattern.
6. Adjust the initial spring set per the Spring
Adjustment section in this manual.
Actuator (Spring-to-Open)
WARNING
Observe the warning at the start of the
Maintenance section.
Refer to figure 4.
Before disassembling the actuator, disassemble the
valve plug, seat ring, and packing according to
instructions in this manual.
Disassembly
1. Unscrew the spring case assembly (key 27). Turn
the adjusting screw nut (key 44) counterclockwise to
remove all spring compression. Remove the
adjusting screw nut, upper spring seat, and spring
(keys 44, 29, and 30)
2. Unscrew the casing cap screws and hex nuts
(keys 45 and 46), and remove the upper casing
assembly (key 23) from the lower casing (key 39).
Remove the cotter pin (key 36) and unscrew the
adjusting stem (key 31).
3. Lift out the diaphragm (key 15), diaphragm plate
(key 40), and stem assembly. Remove the travel
indicator (key 32) when the bottom of the stem
enters the yoke window.
4. To replace the diaphragm (key 15), separate the
diaphragm assembly by using a wrench on the hex
nuts (key 42) to unscrew the assembly.
5. Separate the parts—diaphragm washer, actuator
O-ring (keys 41 and 25), diaphragm, and diaphragm
plate, (keys 15 and 40).
6. Inspect the diaphragm and the actuator O-ring for
damage or deterioration, and replace if necessary. If
the diaphragm is replaced, a new O-ring should also
be installed.
7. Inspect the stem O-ring (key 19) and bonnet
bushing (key 20); replace if necessary. To inspect
the casing O-ring (key 18), remove the cap screws
(key 38) and lift off the lower casing (key 39).
Replace the O-ring if necessary. Inspect the
adjusting stem bushing (key 26) and actuator stem
O-ring (key 53). Replace if necessary.
8. If the hammer nut needs to be removed from the
bonnet, the spring pins (key 7) can be removed with
locking pliers.
Assembly
1. Before starting assembly, make sure all parts are
clean and in good condition. There should be no
burrs or sharp edges on any threads or surfaces that
might cut or damage an O-ring, bushing, the
packing, or the diaphragm. When replacing O-rings
and bushings, be sure the O-ring or bushing groove
is clean and undamaged. Using a general purpose
lubricant (key 49), lubricate all bushings and O-rings
and the threads of parts that have to pass through
the bushings and O-rings.
CAUTION
The threads on factory-produced valve
stems have been specially machined
to avoid O-ring, bushing, or packing
damage during trim maintenance. Use
of other than a factory-produced valve
stem may result in early stem O-ring,
bushing, and packing failure.
Note
Do not lubricate cap screws (key 38)
before inserting them in the following
procedure.
2. Place the hammer nut and spring pins on the
bonnet, if removed. Install the casing O-ring
(key 18), the stem O-ring (key 19), and the bonnet
bushing (key 20). Position the lower casing (key 39)
on the bonnet. Insert the nonlubricated cap screws
(key 38), and torque to 49 NSm (36 lbfSft).
3. Assemble the diaphragm plate assembly. Place
the patterned side of the diaphragm (key 15) against
the diaphragm plate (key 40). Be sure to turn the
diaphragm washer (key 41) so that the side that is
beveled on the inside diameter is against the O-ring

D4 Valve
Instruction Manual
Form 5755
September 2005
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(key 25). Also, make sure that it is assembled for
installation with the diaphragm on the loading
pressure side and the lockwasher (key 43) and
diaphragm washer (key 41) are on the upper side.
Note
Spring pins must always be in place
during valve operation, acting as a
safeguard against injury when the unit
is being disassembled.
4. Fasten the diaphragm and diaphragm plate
assembly on the stem with hex nuts (key 42). Place
the diaphragm and diaphragm plate, and stem
assembly into the lower casing and bonnet. Install
the travel indicator (key 32) on the stem as the
bottom of the stem enters the yoke window.
5. Screw the adjusting stem (key 31) onto the stem
(key 47) and secure the cotter pin (key 36). Make
sure the bushing and O-ring are in place in the upper
casing.
CAUTION
Over-tightening the diaphragm casing
cap screws and nuts (keys 45 and 46)
can damage the diaphragm. Do not
exceed 27 NSm (20 lbfSft) torque.
6. Position the upper casing (key 23) on the lower
casing (key 39). Insert the cap screws (key 45) and
tighten the hex nuts (key 46). Torque the casing cap
screws evenly to 27 NSm (20 lbfSft) using a
crisscross pattern.
7. Replace the spring (key 30), spring seat (key 29),
and adjusting stem nut (key 44) over the adjusting
stem. Replace the spring case assembly (key 27).
8. Adjust the initial spring set per the Spring
Adjustment section in this manual.
Parts Ordering
Each Design D4 control valve is assigned a serial
number, which can be found on the nameplate.
Refer to the number when contacting your Fisher
representative for assistance or when ordering
replacement parts.
Note
Use only genuine Fisher replacement
parts. Components that are not
supplied by Fisher should not, under
any circumstances, be used in any
Fisher valve, because they will void
your warranty, might adversely affect
the performance of the valve, and
might jeopardize worker and
workplace safety.
Note
Neither Emerson, Emerson Process
Management, Fisher, nor any of their
affiliated entities assumes
responsibility for the selection, use
and maintenance of any product.
Responsibility for the selection, use,
and maintenance of any product
remains with the purchaser and
end-user.
Repair Kits
Note
All repair kits are supplied with
hydrogenated nitrile bonnet O-ring.
Viton bonnet O-ring must be ordered
separately when required.
Description Part Number
* Packing Repair Kit
Includes key numbers 4, 8, 12 (2 req’d),
and 13 RD4X0000012
* Actuator Repair Kit
Includes key numbers 4, 8, 12 (2 req’d), 13,
15, 18, 19, 20, 25, 26, 36, and 53 RD4X0000022

D4 Valve
Instruction Manual
Form 5755
September 2005
11
Parts List
Key Description Part Number
1 Valve Body
2* Valve Plug
S41000 / S41600 HT
1-inch valve
0.25 inch port diameter 20C3692X012
0.375 inch port diameter 20C3693X012
0.5 inch port diameter 20C3694X012
0.75 inch port diameter GE01557X012
2-inch valve
0.25 inch port diameter GE00992X012
0.375 inch port diameter GE00993X012
0.5 inch port diameter GE00994X012
0.75 inch port diameter GE01558X012
1-inch port diameter GE01561X012
1.25 inch port diameter GE01555X012
S17400 H1150 Dbl
1-inch valve
0.25 inch port diameter 20C3692X032
0.375 inch port diameter 20C3693X032
0.5 inch port diameter 20C3694X032
0.75 inch port diameter GE01557X032
2-inch valve
0.25 inch port diameter GE00992X032
0.375 inch port diameter GE00993X032
0.5 inch port diameter GE00994X032
0.75 inch port diameter GE01558X032
1-inch port diameter GE01561X032
1.25 inch port diameter GE01555X032
Tungsten Carbide
1-inch valve
0.25 inch port diameter 20C3696X012
0.375 inch port diameter 20C3697X012
0.5 inch port diameter 20C3698X012
0.75 inch port diameter 20C3699X012
2-inch valve
0.25 inch port diameter 20C3682X012
0.375 inch port diameter 20C3683X012
0.5 inch port diameter 20C3685X012
0.75 inch port diameter 20C3686X012
1-inch port diameter 20C3687X012
1.25 inch port diameter 20C3688X012
3* Seat Ring
S17400 H1150 Dbl
1-inch valve
0.25 inch port diameter GE00982X032
0.375 inch port diameter GE00983X032
0.5 inch port diameter GE00984X032
0.75 inch port diameter GE00985X032
2-inch valve
0.25 inch port diameter GE00986X032
0.375 inch port diameter GE00987X032
0.5 inch port diameter GE00988X032
0.75 inch port diameter GE00989X032
1-inch port diameter GE00990X032
1.25 inch port diameter GE00991X032
Tungsten Carbide
1-inch valve
0.25 inch port diameter GE07347X012
0.375 inch port diameter GE07363X012
0.5 inch port diameter GE07364X012
0.75 inch port diameter GE07365X012
Key Description Part Number
2-inch valve
0.25 inch port diameter GE07389X012
0.375 inch port diameter GE07394X012
0.5 inch port diameter GE07397X012
0.75 inch port diameter GE07398X012
1-inch port diameter GE07399X012
1.25 inch port diameter GE07406X012
4* Groove Pin GE01163X012
5 Bonnet
6 Hammer Nut
7 Spring Pin
8* Bonnet O-ring
Hydrogenated Nitrile
–46 to 149_C (–50 to 300_F) 10C3680X012
Viton, –23 to 204_C (–10 to 400_F) 10C3680X022
9* Seat Ring Gasket
For 1-inch valve 1B198636042
For 2-inch valve 1B198836042
10 Packing Retainer
11 Belleville Springs
12* Anti-Extrusion Washer, 2 req’d 12B6335X022
13* Packing Set 12B6667X012
14 Packing Spacer
15* Diaphragm 22B3521X012
16 Nameplate
17 Drive Screw
18* Casing O-ring 1F9141X0142
19* Stem O-ring 1K7561X0072
20* Bonnet Bushing 17A7112X012
22 Locknut
23 Upper Casing Assembly
25* Actuator O-ring 1K7561X0072
26* Adjusting Stem Bushing (spring-to-open only) 17A4059X012
27 Spring Case Assembly
28 Lower Spring Seat
29 Upper Spring Seat
30 Spring
Spring-to-Close, Light Rate 1F176827092
Spring-to-Close, Heavy Rate 1E792427082
Spring-to-Open, Light Rate 1F176727032
Spring-to-Open, Heavy Rate 1F714327092
31 Adjustment Screw or Stem
32 Travel Indicator
34 Vent Assembly
36* Cotter Pin (spring-to-open only) 1C608035022
37 Pipe Plug
38 Cap Screw
39 Lower Casing
40 Diaphragm Plate
41 Diaphragm Washer
42 Hex Nut
43 Lockwasher
44 Adjustment Screw Nut
45 Cap Screw
46 Hex Nut
47* Valve Stem
Nitronic 50, Reverse Acting 20C3681X022
Nitronic 50, Direct Acting 20C3716X022
49 Lubricant (lithium grease or equivalent)
50 NACE Tag (not shown)
51 Drive Screw
53* Actuator Stem O-ring (spring-to-open only) 1C7821X0182
54 Lubricant (anti-seize or equivalent)
55 Spring Setting Label (not shown)
*Recommended spare parts

D4 Valve
Instruction Manual
Form 5755
September 2005
12
GE02332-A
Figure 3. Design D4 Valve Assembly (Spring-to-Close)

D4 Valve
Instruction Manual
Form 5755
September 2005
13
Figure 4. Design D4 Valve Assembly (Spring-to-Open)
2 PLACES
GE02334-B

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Instruction Manual
Form 5755
September 2005
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D4 Valve
Instruction Manual
Form 5755
September 2005
15

D4 Valve
Instruction Manual
Form 5755
September 2005
16
Fisher
Marshalltown, Iowa 50158 USA
Cernay 68700 France
Sao Paulo 05424 Brazil
Singapore 128461
Emerson Process Management
www.Fisher.com
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are
not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability.
We reserve the right to modify or improve the designs or specifications of such products at any time without notice.
Neither Emerson, Emerson Process Management, Fisher, nor any of their affiliated entities assumes responsibility for the selection, use and
maintenance of any product. Responsibility for the selection, use and maintenance of any product remains with the purchaser and end-user.
EFisher Controls International LLC 2002, 2005; All Rights Reserved Printed in USA
Micro-Form and Fisher are marks owned by Fisher Controls International LLC, a member of the Emerson Process Management business division
of Emerson Electric Co. Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. All other marks are the
property of their respective owners.