Jflow controls DM4800 SERIES Manual

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: [phone]
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.
1

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.
2
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: [phone]
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

3
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: [phone]
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*
4
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: [phone]
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