Metso Jamesbury 4000 B Operating and maintenance manual

Series 4000 Model B
3-Piece Ball Valves with ISO Bonnet
1/2" – 2" (DN 15 – 50) Standard Bore,
1/2" – 1-1/2" (DN 15 – 40) Full Bore
Installation, Maintenance and
Operating Instructions
IMO-210EN • 5/2011

2 IMO-210EN
Table of Contents
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 REPAIR KITS/SPARE PARTS . . . . . . . . . . . . . . . . . . . . 5
5 EXPLODED VIEW AND PARTS LIST . . . . . . . . . . . . . 6
READ THESE INSTRUCTIONS FIRST!
This instruction manual contains important information regarding the installation, operation, and troubleshooting
of the Jamesbury® Series 4000 Model B Three-Piece Ball Valves with ISO Bonnet. Please read these instructions
carefully and save them for future reference.
SAVE THESE INSTRUCTIONS!
Subject to change without notice.

3
1
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IMO-210EN
GENERAL
This instruction manual contains important information
regarding the installation, operation and troubleshooting
for the Jamesbury 1/2" – 2" (DN 15 – 50) Standard Bore,1/2"
– 1-1/2" (DN 15 – 40) Full Bore Series 4000 Model B 3-
Piece Ball Valves with ISO Bonnet. Please read the instruc-
tions carefully and save them for future reference.
1.1 WARNING
FOR YOUR SAFETY, TAKE THE FOLLOWING PRECAUTIONS BEFORE
REMOVING THE VALVE FROM THE LINE, OR BEFORE ANY DISASSEM-
BLY.
1. DURING REMOVAL AND DISASSEMBLY, WEAR ANY PROTECTIVE
EQUIPMENT NORMALLY REQUIRED TO PROTECT AGAINST DIS-
CHARGE OF TRAPPED FLUID.
2. DEPRESSURIZE THE LINE AND VALVE AS FOLLOWS:
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE
LINE.
B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE
BODY CAVITY BEFORE REMOVAL FROM THE LINE.
C. AFTER REMOVAL,AND BEFORE ANY DISASSEMBLY, CYCLETHE
VALVE AGAIN SEVERAL TIMES.
3. SEAT AND BODY RATINGS - THE PRACTICAL AND SAFE USE OF
THIS PRODUCT IS DETERMINED BY BOTH THE SEAT AND BODY
RATING. READ THE NAME TAG AND CHECK BOTH RATINGS. THIS
PRODUCT IS AVAILABLE WITH A VARIETY OF SEAT MATERIALS.
SOME OF THE SEAT MATERIALS HAVE PRESSURE RATINGS THAT
ARE LESS THAN THE BODY RATINGS. ALL OF THE BODY AND
SEAT RATINGS ARE DEPENDENT ON VALVE TYPE AND SIZE,
SEAT MATERIAL AND TEMPERATURE. DO NOT EXCEED THESE
RATINGS.
NOTE: OPTIONAL ROUND AND OVAL HANDLES ARE AVAILABLE FOR
THESE VALVES IN PLACE OF LEVER HANDLES.
INSTALLATION
Screwed End Style - Use standard piping practices to
install valves with threaded end caps. When tightening
valve to pipe, apply wrench to end cap nearest the pipe
being worked.
Weld End Style - Only valves with UHMWPE or Delrin®
seats must be disassembled before welding in line. A
warning tag and replacement body seals are affixed to
valves with these seat materials. VALVES WITH OTHER SEAT
MATERIALS SHOULD BE WELDED IN-LINE FULLY ASSEMBLED.
1. Only a qualified person should weld, as outlined in
Section IX of the ASME Boiler Construction Code.
2. Cycle the valve to the fully open position.
3. Remove or protect the handle or actuator from weld
splatter or arc strikes.
4. Weld by applying a recommended 1/8" (3.2 mm) max.
weld bead per pass around each end cap. CAUTION:
DO NOT heat the center section over 350˚F (176.7˚C).
Use a temperature stick and a wet cloth wrapped
around the center section to prevent overheating.
5. For welds that require multiple passes to achieve weld
size,stop after each pass and carefully monitor the valve
body temperature.
6. After sufficient cooling of the valve, replace the handle
or actuator.
IMPORTANT: If the body seals (6) and (18) are removed for
welding, DO NOT REUSE THEM. When reassembling the
valve, put new seals back into the grooves. Body seal kits
are provided in (Table 5). Tighten the body bolts to the
torques listed in (Table 1).
TABLE 1
Body Bolt / Hex. Nut Torque
Valve Size
Full Port Size In ( ) Torque FT•LBS Torque N•m
1/2" (1/2")
DN 15 (DN 15) 10 13
3/4"
DN 20 14 19
1" & 1-1/4" (3/4" & 1")
DN 25 & 32 (DN 20 & 25) 26 35
1-1/2" & 2" (1-1/4" & 1-1/2")
DN 40 & 50 (DN 32 & 40) 63 85
CAUTION: IF THE VALVE IS BEING DISASSEMBLED FOR
WELDING, DO NOT CUT OR SCRATCH THE SEATS, SEALS
AND SEALING SURFACES. DAMAGE TO THE SEALING
SURFACES MAY CAUSE LEAKAGE.
After valve is in line,or before any testing,tighten compression
plate hex.head cap screws according to the MAINTENANCE
Section below.
3 MAINTENANCE
Routine maintenance consists of tightening the compression
plate hex. head cap screws periodically to compensate for
the wear caused by the stem turning against the stem seals.
Check to make sure that the compression plate hex. head
cap screws are tightened to the torque listed in (Table 2).
Overhaul maintenance consists of replacing seats and seals.
A standard service kit consisting of these parts may be
obtained from your Jamesbury Distributor (see Table 4).

4 IMO-210EN
TABLE 2
Hex. Head Cap Screw Torque
Valve Size
Full Port Size In ( ) Torque IN•LBS Torque N•m
1/2" & 3/4" (1/2")
DN 15 & 20 (DN 15) 15 1.7
1" & 1-1/4" (3/4" & 1")
DN 25 & 32 (DN 20 & 25) 20 2.3
1-1/2" & 2" (1-1/4" & 1-1/2")
DN 40 & 50 (DN 32 & 40) 32 3.6
3.1 Disassembly
The Series 4000 ball valve is designed to be serviced in or
out of the line. The following instructions are for in-line
disassembly. (For bench disassembly, which may be more
convenient, follow a similar sequence).
1. Comply fully with the instructions in the WARNING
Section on page one.
2. Be sure to cycle the valve.Leave in the open position.The
body center section will not swing out in the closed
position.
3. Remove the handle nut (16) and handle (17).
4. Loosen all four body bolts (52).Remove three from the
valve. Leave the remaining bolt in place with the hex
nut (53) backed off at least 1/4" (6.4 mm).
5. For positive alignment and ease of in-line assembly,
each end cap is interlocked approximately 1/16" (1.6
mm) into the body as shown in (Figure 3).To overcome
this feature during in-line disassembly it is necessary to
separate each cap at least 1/8" (3.2 mm) from the body.
Sharply rap body and caps with a block of wood or
plastic mallet to break loose body seal. Spread end
caps and swing the body out of the line. If pipe does
not allow simple spreading, remove the remaining
body bolt and rotate center section per (Figure 1).This
will improve access to the end cap flange for ease of
spreading. Swing the valve body (1) out from between
the end cap (2). Be careful not to damage the sealing
surfaces "A" (see Figure 3) at each end of the valve.
6. Turn the stem (4) so that the valve is fully closed.
Remove the inner body seals (6) and outer body seals
(18) and the seats (5). NOTE: On those valves with
metal seats (DH seat/seal code), there is a one piece
body seal (6). Body seals will be tightly compressed in
their grooves. Use extreme care when prying them
out. Damage such as scratches to the bottom of the
groove will cause leaks. If the seats are not easily
removed, gently tap the ball (3) with a piece of wood or
other soft material.
7. Remove the ball (3).
8. Remove the hex.head cap screws (29),disc springs (31)
and compression plate (20).
9. Press the stem (4) from the top into the valve body (1)
and remove it through the end of the body.
10. Carefully pry out and discard the old stem seal (8)
being careful not to damage the stem seal bore in the
body. On Fire-Tite® valves, carefully pry out the stem
bearings (13) and the secondary stem seal (7), being
careful not to damage the bearing surfaces. NOTE: On
non Fire-Tite valves there is only one lower stem
bearing (24). Also, valves with graphite stem seals (8)
have an additional upper stem bearing (10) and an
anti-extrusion ring (55).
3.2 Assembly
The following instructions are for in-line assembly.For bench
assembly, which may be more convenient, follow a similar
sequence by holding the valve in a vise by one end cap.Use
care not to cut or scratch the seats, seals or sealing surface.
1. With the valve swung to the out-of-line position, insert
from the inside of the body a stem bearing (13), a sec-
ondary stem seal (7),then another stem bearing (13) into
the stem bore. For non Fire-Tite valves use one stem
bearing (24). See (Figure 3) and parts list (Figure 4).
2. Insert the stem (4) horizontally into the body bore
(threaded end first). The blade at the ball end of the
stem must be vertical (see Figure 2). Guide the stem
into the stem bore being careful not to scratch the
bearings.
Figure 1 Figure 2

5IMO-210EN
Figure 3
NON FIRE-TESTED
FIRE-TESTED Surface A
1/16" (1.6 mm)
Interlock
3. Holding the stem in place from the bottom, install the
stem seal (8) and the compression plate (20).For valves
with graphite stem seals (8),install upper stem bearing
(10) and anti-extrusion ring (55) prior to installing the
stem seal (8).
4. Place the disc springs (31) on top of the compression
plate over the bolt holes and insert the hex. head cap
screws (29) and bring them down hand tight with the
disc springs. NOTE: See (Figure 4) for proper disc
spring orientation.
5. While pressing the stem upward from inside the body,
torque the hex head cap screws (29) applying the
torque shown in (Table 2). Apply torque evenly alter-
nating between the two hex head cap screws so that
compression plate will be parallel with the valve body
bonnet.
6. Align the stem blade with the ball slot. Insert the ball
(3) and then rotate the stem (4) so that the ball is in the
closed position.
7. Working at either end of the body (1), place a seat (5)
into the body. Fit it snugly against the closed ball.
NOTE: The sealing surface of the seat is toward the ball
(see Figure 4).
8. Place an inner body seal (6) and an outer body seal (18)
into the machined sealing groove of the body cap (2)
(see Figure 3).NOTE: On those valves with metal seats
(DH seat/seal code), there is a one piece body seal (6).
Be certain that the groove and seal are clean.
9. Repeat steps 7 and 8 for assembly at the opposite end.
10. Turn the stem so that the ball is in the full open position.
11. Swing the entire body assembly back into the properly
aligned and interlock position between the body caps,
being careful not to scratch the body seals. Body caps
may have to be spread slightly to accept the body.
12. Close the valve.
13. Bolt the valve together with lubricated body bolts (52)
and hex. nuts (53). Tighten these bolts evenly and
alternately. (See Table 1 for the torques.)
14. Attach the handle (17) and secure it with the handle nut
(16) applying the torque shown in (Table 3).
TABLE 3
Handle Nut Torque
Valve Size
Full Port Size In ( ) Torque IN•LBS Torque N•m
1/2" & 3/4" (1/2")
DN 15 & 20 (DN 15) 9 1.0
1" & 1-1/4" (3/4" & 1")
DN 25 & 32 (DN 20 & 25) 23 2.6
1-1/2" & 2" (1-1/4" & 1-1/2")
DN 40 & 50 (DN 32 & 40) 33 3.7
4 REPAIR KITS/SPARE PARTS
For further information on spare parts and service or
assistance visit our web-site at www.jamesbury.com.
NOTE: Service kits include two seats (5), one stem seal (8),
two stem bearings (13), one secondary stem seal (7), one
stem bearing (24), two inner body seals (6) and two outer
body seals (18). Consult the factory for replacement parts
of valves with seat materials not listed or for special services.

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IMO-210EN
PARTS LIST
EXPLODED VIEW AND PARTS
16
Proper Disc Spring
Orientation
19
53
29
31
2 20
18
6
5
8
25
26
1
10
8
55
ITEM
1
2
3
4
5
6
7*
8
10†
13*
16
17
18
19
20
22**
23**
24***
25
26
29
31
52
53
54****
55†
PART NAME QTY
Body 1
BodyCap 2
Ball 1
Stem 1
Seat 2
Inner Body Seal 2
Secondary Stem Seal 1
Stem Seal 1
Stem Bearing 1
Stem Bearing 2
Handle Nut 1
Handle 1
Outer Body Seal 2
Shakeproof Washer 1
Compression Plate 1
Identification Tag 1
Pop Rivet 2
Stem Bearing Non Fire-Tite 1
Socket Head Cap Screw 1
Spacer 1
Hex. Head Cap Screw 2
Disc Spring 4
Body Bolt 4
Hex Nut 4
Weld End Tag 1
Anti-Extrusion Ring 1
* Fire-Tite Valves Only
** ANSI Valves Only
*** Non Fire-Tite Valves Only
**** Socket Weld and Butt Weld Valves Only
† Used for Graphite Upper Stem Seals Only
3
5
6
18
13 2
7
13
22 52
4 24
23
Figure 4

7IMO-210EN
TABLE 4
Service Kits Valve Size – Full Port Size Shown in ( )
Valve Size 1/2" (1/2")
DN 15 (DN 15)
3/4"
DN 20
1" (3/4")
DN 25 (DN 20)
1-1/4" (1")
DN 32 (DN 25)
1-1/2" (1-1/4")
DN 40 (DN 32)
2" (1-1/2")
DN 50 (DN 40)
PTFE Seats RKN-354-TT RKN-355-TT RKN-356-TT RKN-357-TT RKN-358-TT RKN-359-TT
Delrin Seats RKN-354-RT RKN-355-RT RKN-356-RT RKN-357-RT RKN-358-RT RKN-359-RT
Peek® Seats RKN-354-LG RKN-355-LG RKN-356-LG RKN-357-LG RKN-358-LG RKN-359-LG
Metal Seats RKN-354-DH RKN-355-DH RKN-356-DH RKN-357-DH RKN-358-DH RKN-359-DH
Xtreme® Seats RKN-354-XT RKN-355-XT RKN-356-XT RKN-357-XT RKN-358-XT RKN-359-XT
PFA Seats RKN-354-BT RKN-355-BT RKN-356-BT RKN-357-BT RKN-358-BT RKN-359-BT
TABLE 5
Body Seal Kits Valve Size – Full Port Size Shown in ( )
Valve Size 1/2" (1/2")
DN 15 (DN 15)
3/4"
DN 20
1" (3/4")
DN 25 (DN 20)
1-1/4" (1")
DN 32 (DN 25)
1-1/2" (1-1/4")
DN 40 (DN 32)
2" (1-1/2")
DN 50 (DN 40)
Standard – TFM + Graphite RKN-348-TT RKN-349-TT RKN-350-TT RKN-351-TT RKN-352-TT RKN-353-TT
Spiral Wnd – 316SS + Graphite RKN-348-DH RKN-349-DH RKN-350-DH RKN-351-DH RKN-352-DH RKN-353-DH
UHMWPE + Graphite RKN-348-UU RKN-349-UU RKN-350-UU RKN-351-UU RKN-352-UU RKN-353-UU

8 IMO-210EN
Subject to change without prior notice.
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