Victaulic 795 Series User manual

WARNING
• Read and understand all instructions before attempting to install, remove, adjust, or maintain any Victaulic piping products.
• Depressurize and drain the piping system before attempting to install, remove, adjust, or maintain any Victaulic piping products.
• Wear safety glasses, hardhat, foot protection, and hearing protection.
Failure to follow instructions and warnings could cause system failure, resulting in death or serious personal injury and property damage.
HANDWHEEL OPERATOR PNEUMATIC OPERATOR HYDRAULIC OPERATOR
I-795/906
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I-795/906INSTALLATION AND MAINTENANCE INSTRUCTIONS
Series 795 and 906 Installation-Ready™Knife Gate Valves

I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
TABLE OF CONTENTS
Hazard Identification ......................................3
Knife Gate Valve Components ...............................4
Handwheel Operator Components ............................5
Pneumatic Operator Components ............................5
Hydraulic Operator Components .............................6
Dimensions – With Handwheel Operator .......................7
Dimensions – With Bevel Gear Operator........................8
Dimensions – With Pneumatic Operator ........................9
Dimensions – With Hydraulic Operator........................10
Dimensions – Seat Cartridge ...............................11
Important Information ....................................12
Recommended Spare Parts and Tools ........................12
Manual Operation .......................................12
Pneumatic Operation .....................................12
Hydraulic Operation ......................................12
SECTION I
Installing the 795 Valve Into a Steel Piping System...............14
Installing the 906 Valve Into an HDPE Piping System.............18
SECTION II
Maintenance ...........................................24
Packing Adjustment....................................24
Lubrication ..........................................24
Removing the Existing Seat Cartridge.........................24
Installing the Replacement Seat Cartridge .....................29
HAZARD IDENTIFICATION
Definitions for identifying the various hazard levels are
provided below. When you see this symbol, be alert to the
possibility of personal injury. Carefully read and fully
understand the message that follows.
DANGER
• The use of the word “DANGER” identifies an immediate
hazard with a likelihood of death or serious personal injury
if instructions, including recommended precautions, are not
followed.
WARNING
• The use of the word “WARNING” identifies the presence
of hazards or unsafe practices that could result in death or
serious personal injury if instructions, including recommended
precautions, are not followed.
CAUTION
• The use of the word “CAUTION” identifies possible hazards or
unsafe practices that could result in personal injury and product
or property damage if instructions, including recommended
precautions, are not followed.
NOTICE
• The use of the word “NOTICE” identifies special instructions
that are important but not related to hazards.
I-795/906_3
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
KNIFE GATE VALVE COMPONENTS
NOTICE
• Drawings and/or pictures in this manual may be exaggerated for clarity.
• Dimensions listed are for reference only. Refer to Victaulic submittal 08.25 or submittal 19.06 for complete dimensional information.
• The product, along with these installation and maintenance instructions, contains trademarks, copyrights, and/or patented features that are
the exclusive property of Victaulic.
BILL OF MATERIALS
Item Qty. Description
1 1 Upper Body
2 1 Lower Body
3 2 Pipe Gasket
4 1 Seat Gasket
5 1 Seat
6 1 Knife Seal
7 1 Knife
8 1 Retaining Plate
9 1 Packing Gland
10 4Full Thread Hex Bolt †
11 4Washer †
12 4Heavy Hex Nut †
13 4Washer
14 4Helical Spring-Lock Washer
15 4Hex Cap Screw
16 1Dowel Pin
17 1Dowel Pin
18 4Hex Bolt
19 4Helical Spring-Lock Washer
20 4Hex Nut
21 1 O-Ring
22 1Plug
23 8Washer
24 2Square Head Set Screw ‡
25 2Spacer Bolt
26 2Retainer *
27 2Hex Cap Screw**
NOTES:
†Items 10, 11, and 12 comprise the assembly hardware.
‡ Item 24 is used for 795 valve (carbon steel) only.
* Item 26 is used for 906 valve (HDPE) only.
** Item 27 is required when servicing the valve. Victaulic offers a kit to replace
the entire seat cartridge. Refer to Section II in this manual for complete removal
and replacement instructions.
7
15
14
13
9
18
8
6
5
4
1
3
3
17
16
2
10
22
NIPPLES
SHOWN FOR
CLARITY
ONLY
21
12 11
20 19 23
24
24
23
25
25
27
26
I-795/906_4
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
BILL OF MATERIALS
Item Qty. Description
1 1 Yoke
2 1 Drive Nut
3 1 Spacer
4 1 Parallel Key
5 1 Handwheel
6 1 Washer
7 1 Stem
8 1 Hex Jam Nut
9 1 Gate Connector
10 1Slotted Spring Pin
11 1Stroke Limiter Assembly
12 1Washer
1
5
8
7
2
4
6
3
9
10
11
12
HANDWHEEL OPERATOR COMPONENTS (3 TO 8 INCH)
BEVEL GEAR COMPONENTS (10 TO 12 INCH)
27
28
29
30
21
23
24
25
22
26
BILL OF MATERIALS
Item Qty. Description
21 1Yoke
22 1Gear Actuator
23 4Washer
24 4Helical Spring-Lock Washer
25 4Hex Cap Screw
26 1Stem
27 1Gate Connector
28 1Slotted Spring Pin
29 1Stroke Limiter Assembly
30 1Washer
I-795/906_5
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
3
4
2
5
1
6
7
8
22
25
27
23
24
28
21
26
29
30
BILL OF MATERIALS
Item Qty. Description
21 1Yoke
22 1Hydraulic Cylinder
23 4Washer
24 4Helical Spring-Lock Washer
25 1Bushing
26 1Gate Connector
27 4Hex Cap Screw
28 4Hex Nut
29 1Stroke Limiter Assembly
30 1Washer
HYDRAULIC OPERATOR COMPONENTS
BILL OF MATERIALS
Item Qty. Description
1 1 Yoke
2 1 Pneumatic Cylinder with Nuts
3 4 Washer
4 4 Helical Spring-Lock Washer
5 1 Bushing
6 1 Gate Connector
7 1 Stroke Limiter Assembly
8 1 Washer
PNEUMATIC OPERATOR COMPONENTS
I-795/906_6
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
DIMENSIONS – WITH HANDWHEEL OPERATOR
VALVE CLOSED
NOT INSTALLED
VALVE OPEN
INSTALLED
VALVE OPEN
INSTALLED
E
C
H
F
Nominal Size
in
DN
Dimensions – inches/millimeters
Weight
lbs
kg
C E F H
30.88 10.25 6.75 32.25 113 . 0 0
DN80 22.4 260.4 171.5 819.2 51.3
40.88 11. 2 5 6.75 34.75 122.00
DN100 22.4 285.8 171.5 882.7 55.3
61.13 13.75 7. 0 0 43.75 166.00
DN150 28.7 349.3 177. 8 1111. 3 75.3
81.63 15.50 7. 0 0 53.25 237.0 0
DN200 41.4 393.7 177. 8 1352.6 107. 5
I-795/906_7
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
DIMENSIONS – WITH BEVEL GEAR OPERATOR
VALVE CLOSED
NOT INSTALLED
VALVE OPEN
INSTALLED
VALVE OPEN
INSTALLED
E
C
H
F
B
J
Nominal Size
in
DN
Dimensions – inches/millimeters
Weight
lbs
kg
B C E F H J
10 11. 2 2 1.75 19.00 7.50 68.50 16.00 465.00
DN250 284.9 44.5 482.6 190.5 1739.9 406.4 210.9
12 11. 2 2 2.00 21.00 7.50 73.00 16.00 497. 0 0
DN300 284.9 50.8 533.4 190.5 1854.2 406.4 225.4
I-795/906_8
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
DIMENSIONS – WITH PNEUMATIC OPERATOR
VALVE CLOSED
NOT INSTALLED
VALVE OPEN
INSTALLED
VALVE OPEN
INSTALLED
H
C
E
F
Nominal Size
in
DN
Dimensions – inches/millimeters
Weight
lbs
kg
C E F H
30.88 10.25 6.75 42.00 126.00
DN80 22.4 260.4 171.5 1066.8 57. 2
40.88 11. 2 5 6.75 44.50 133.00
DN100 22.4 285.8 171.5 1130. 3 60.3
61.13 13.75 7.0 0 53.75 215.00
DN150 28.7 349.3 177. 8 1365.3 97.5
81.63 15.50 7. 0 0 55.75 348.00
DN200 41.4 393.7 177. 8 1416.1 157.9
10 1.75 19.00 7.50 79.50 550.00
DN250 44.5 482.6 190.5 2019.3 249.5
12 2.00 21.00 7. 50 86.50 586.00
DN300 50.8 533.4 190.5 2197.1 265.8
I-795/906_9
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
DIMENSIONS – WITH HYDRAULIC OPERATOR
VALVE CLOSED
NOT INSTALLED
VALVE OPEN
INSTALLED
VALVE OPEN
INSTALLED
H
C
E
F
Nominal Size
in
DN
Dimensions – inches/millimeters
Weight
lbs
kg
C E F H
30.88 10.25 6.75 43.88 115 .0 0
DN80 22.4 260.4 171.5 1114. 6 52.2
40.88 11. 2 5 6.75 46.50 125.0 0
DN100 22.4 285.8 171.5 1181.1 56.7
61.13 13.75 7.0 0 55.00 172.00
DN150 28.7 349.3 177. 8 1397. 0 78.0
81.63 15.50 7. 0 0 66.50 259.00
DN200 41.4 393.7 177. 8 1689.1 117.5
10 1.75 19.00 7.50 80.25 462.00
DN250 44.5 482.6 190.5 2038.4 209.6
12 2.00 21.00 7. 50 89.50 525.00
DN300 50.8 533.4 190.5 2273.3 238.1
I-795/906_10
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
DIMENSIONS – SEAT CARTRIDGE
E
H
F
Nominal Size
in
DN
Dimensions – inches/millimeters
Weight
lbs
kg
E F H
39.88 3.88 10.88 16.30
DN80 251.0 98.6 276.4 7.4
410.75 3.88 12.13 19.70
DN100 273.1 98.6 308.1 8.9
613.00 3.88 15.00 28.90
DN150 330.2 98.6 381.0 13.1
815.50 3.88 18.25 40.70
DN200 397. 3 98.6 463.6 18.5
10 19.00 5.00 23.00 82.00
DN250 482.6 127. 0 584.2 37.2
12 20.63 5.00 25.50 100.60
DN300 524.0 127. 0 6 47. 7 45.6
I-795/ 906_11
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
IMPORTANT INFORMATION
• Series 795 Installation-Ready™Knife Gate Valves are designed
for installation with grooved-end carbon steel or stainless steel
NPS pipe. For other pipe sizes and materials, contact Victaulic.
Welding of pipe ends to the valve is not permitted. Refer to the
Victaulic I-100 Field Installation Handbook for pipe preparation
requirements. The I-100 can be downloaded at victaulic.com.
• Series 906 Installation-Ready™Knife Gate Valves are designed for
installation with plain-end HDPE pipe. Refer to the Victaulic I-900
Field Installation Handbook for pipe preparation requirements. The
I-900 can be downloaded at victaulic.com.
• Installation-Ready™Knife Gate Valves are rated for a maximum
working pressure of 150 psi/10 Bar.
• Installation-Ready™Knife Gate Valves are not intended for throttling
service. These valves are designed for shutoff applications only.
• Installation-Ready™Knife Gate Valves are not intended for use in
air services.
• Installation-Ready™Knife Gate Valves can be installed in any
orientation. NOTE: Additional supports shall be considered when
a 795 valve is installed horizontally, especially when a pneumatic,
electric, or hydraulic actuator is used. The 906 valve must be fully
supported in all installations.
• Installation-Ready™Knife Gate Valves and connecting piping must
be supported properly to prevent the joints from being subjected to
bending loads, shear loads, or any other external loads.
• DO NOT use Installation-Ready™Knife Gate Valves as a jack for
pipe alignment or support.
• DO NOT climb on or stand on Installation-Ready™Knife Gate
Valves or other piping system components.
RECOMMENDED SPARE PARTS AND TOOLS
CAUTION
• Ensure that all spare seals and gaskets are compatible with the
line temperature and media.
Failure to follow this instruction will cause gasket degradation,
resulting in joint leakage and property damage.
• Spare Seat Cartridge
• Ratchet Wrenches
• Crescent Wrenches
• Pipe Wrenches
• Victaulic Lubricant or Silicone Lubricant
• Water-Stabilized Calcium Grease Containing Graphite and
Molybdenum Disulfide
• Anti-Seize Compound
MANUAL OPERATION
For Installation-Ready™Knife Gate Valves installed with a handwheel operator, the following table contains the approximate number of complete
rotations required during standard operation (i.e. going from fully closed to fully open) or during maintenance to remove the seat cartridge.
Valve Size
inches
mm
Thrust Load
lbs
N
Approximate
Number of
Handwheel
Rotations
for Standard
Operation
Approximate
Number of
Handwheel
Rotations for
Maintenance
Maximum
Torque
Required
ft-lbs
N•m
Rim Pull
Effort
lb
N
31500 20 45 11 16
80 6672 14 70
42100 25 55 15 22
100 9341 20 99
63000 35 70 22 33
150 13,344 29 145
84600 45 90 33 49
200 20,461 44 217
10* 7000 44 88 72 43
250 31,136 98 189
12* 7200 52 100 73 43
300 32,026 99 192
* These sizes come standard with a bevel gear operator.
PNEUMATIC OPERATION
Pneumatic cylinders are designed to be operated within 80–150 psi/6–10 Bar air pressure. Contact Victaulic if your system air pressure is less than
80 psi/6 Bar. Additional information will be required to determine appropriate specifications for your system.
HYDRAULIC OPERATION
Hydraulic cylinders are designed to be operated within 1500–3000 psi/103–207 Bar hydraulic pressure. Contact Victaulic if your system hydraulic
pressure is less than 1500 psi/103 Bar. Additional information will be required to determine appropriate specifications for your system.
I-795/906_12
REV_D

SECTION I
• Installing the 795 Valve
Into a Steel Piping System
• Installing the 906 Valve
Into an HDPE Piping
System
I-795_13
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
INSTALLING THE 795 VALVE INTO A STEEL
PIPING SYSTEM
WARNING
• This valve is intended for use on grooved-end carbon steel or
stainless steel NPS pipe and is NOT to be used on HDPE pipe.
Failure to follow this instruction could result in personal injury,
joint leakage, and property damage, and could void the product
warranty.
1. DO NOT REMOVE OR ADJUST THE ASSEMBLY HARDWARE:
Series 795 Installation-Ready™Knife Gate Valves are designed so
that the installer does not need to remove the assembly hardware for
installation. This design facilitates installation by allowing the installer to
directly insert a grooved pipe end into each opening of the valve.
2. INSPECT PIPE ENDS: The outside surface of the pipe, between the
groove and the pipe end, must be smooth and free from indentations,
projections, weld seams, and roll marks to ensure a leak-tight seal. All
oil, grease, loose paint, dirt, and cutting particles must be removed. The
pipe OD, groove dimensions, and maximum allowable flare diameter
must be within the tolerances published in current Victaulic grooving
specifications. NOTE: Maximum allowable pipe ovality shall comply
with the requirements of ASTM A-999 and API 5L. Greater variations
between the major and minor pipe diameters will result in difficult
assembly and potential joint leakage.
3. INSPECT PIPE GASKETS: Check the pipe gaskets to ensure that
they are suitable for the intended service. The color code identifies the
gasket grade. Refer to Victaulic publication 05.01 in the G-100 General
Catalog for the color code chart.
CAUTION
• A compatible lubricant must be used to prevent the pipe gaskets
from pinching/tearing during installation.
• Pipe gaskets are designed for one-time use only. DO NOT
attempt to reuse pipe gaskets that have been placed in service.
Failure to follow these instructions will cause gasket degradation,
resulting in joint leakage and property damage.
Lubricate
4. LUBRICATE PIPE GASKETS: Apply a thin coat of Victaulic Lubricant
or silicone lubricant only to the sealing lips of the pipe gaskets’ interior.
NOTE: The exterior surface of the pipe gaskets is supplied with a
factory-applied lubricant.
NOTICE
• It is not necessary to remove the pipe gaskets from the valve to
apply additional lubricant to the exterior surface.
TABLE 1: LUBRICANT COMPATIBILITY
Lubricant
Compatibility
with Grade “T”
Nitrile Gaskets
Compatibility
with Grade “E”
EPDM Gaskets
Victaulic Lubricant,
Soap-Based Solutions, Glycerin,
Silicone Oil, or Silicone Release Agent
Good Good
Corn Oil, Soybean Oil,
Hydrocarbon-Based Oils,
or Petroleum-Based Greases
Good Not
Recommended
WARNING
• Keep hands away from the pipe ends and
the openings of the valve when attempting to
insert grooved pipe ends into the valve.
Failure to follow this instruction could result in
serious personal injury.
I-795/906_14
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
5a. ASSEMBLE JOINT: Assemble the joint by inserting a grooved pipe
end into each opening of the valve.
Inspect
5b. INSPECT KEYS: Each grooved pipe end must be inserted into
the valve until contact with the seat occurs, as shown above. This will
ensure that the valve body’s keys align with the grooves in the pipe
ends.
5c. REMOVE ONLY THE SPACER BOLTS: There is one spacer bolt
on each bolt pad to maintain spacing between the bolt pads during
shipping and assembly. After inserting pipe, remove only the spacer
bolts and the attached warning tags before tightening the four nuts in
step 6.
CAUTION
• Spacer bolts are designed to keep the valve’s housings at the
proper spacing during installation of the pipe ends.
• These spacer bolts must be removed prior to tightening the hex
nuts to bring the bolt pads into metal-to-metal contact. The
bolts will prevent proper tightening of the valve housings.
Failure to follow these instructions will cause damage to the valve
components. This may result in joint leakage or property damage,
and could void the product warranty.
NOTE: Do NOT discard the spacer bolts. Reinstall the spacer bolts
to finger-tight after valve installation is complete. If the valve must be
removed from the system, the spacer bolts will be necessary to separate
housings and maintain spacing (dimension "C", as defined in the
dimension tables found on pages 7–10) between the bolt pads during
storage, shipping, and reinstallation.
6. TIGHTEN NUTS: Tighten the hex nuts evenly by alternating sides
in a crossing pattern (as shown in the sequence above) until metal-to-
metal contact occurs at the bolt pads. Ensure that the valve body’s keys
engage the grooves completely during tightening.
NOTE: It is important to tighten the hex nuts evenly by alternating sides
to prevent pinching of the pipe gaskets. An impact wrench or standard
socket wrench with a deep-well socket can be used to bring the bolt
pads into metal-to-metal contact. Refer to the “Series 795 Helpful
Information” and “Impact Wrench Usage Guidelines” sections.
WARNING
• Visual inspection of each joint is critical.
• Improperly assembled joints must be corrected before the
system is placed into service.
Failure to follow these instructions could cause joint failure,
resulting in serious personal injury and/or property damage.
I-795/906_15
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
GOOD
BAD
7. INSPECT PADS: Visually inspect the bolt pads at each joint to ensure
that metal-to-metal contact is achieved across the entire bolt pad
section. 8. TIGHTEN 360° POSITIONING BOLTS: Tighten the two 360°
positioning bolts evenly by alternating sides until they reach a nominal
torque of 40 ft-lbs/54.23 N•m.
I-795/906_16
REV_D

I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
NOTICE
A locking pin is provided to assist with Lockout/Tagout procedures
during installation and maintenance. Ensure that the pin is
removed before attempting to place the valve into service.
IMPACT WRENCH USAGE GUIDELINES
WARNING
• It is important to tighten the nuts evenly by alternating sides
until metal-to-metal contact occurs at the bolt pads.
• DO NOT continue to tighten the nuts after the visual installation
guidelines for the product are achieved.
Failure to follow these instructions could cause gasket pinching and
product damage, resulting in joint failure, serious personal injury,
and property damage.
Due to the speed of assembly when using an impact wrench, the
installer should take extra care to ensure that nuts are tightened evenly
by alternating sides until proper assembly is complete. Always refer to
the specific product installation instructions for complete installation
requirements.
Impact wrenches do not provide the installer with direct “wrench feel” or
torque to judge nut tightness. Since some impact wrenches are capable
of high output, it is important to develop a familiarity with the impact
wrench to avoid damaging or fracturing the bolts or the bolt pads during
installation. DO NOT continue to tighten the nuts after the visual
installation guidelines are achieved.
If the battery is drained or if the impact wrench is under-powered, a new
impact wrench or a new battery pack must be used to ensure that the
visual installation guidelines for the product are achieved.
Perform trial assemblies with the impact wrench and check the
assemblies with socket or torque wrenches to help determine the
capability of the impact wrench. Using the same method, periodically
check additional nuts throughout the system installation.
For safe and proper use of impact wrenches, always refer to the impact
wrench manufacturer’s operating instructions. In addition, verify that
proper impact grade sockets are being used for product installation.
WARNING
Failure to follow instructions for tightening product hardware could
result in:
• Bolt fractures
• Damaged or broken bolt pads or product fractures
• Joint leakage
Series 795 Helpful Information
Valve
Size
Spacer
Bolt Size
Spacer Bolt
Socket
inches/mm
Coupling
Nut
Size
Coupling Nut
Deep-Well Socket
inches/mm
3⁄" - 16 UNC x 2" ⁄ ½" - 13 Heavy Hex ⁄
14 19
4⁄" - 16 UNC x 2" ⁄ ½" - 13 Heavy Hex ⁄
14 19
6⁄" - 16 UNC x 3" ⁄ ⁄" - 11 Heavy Hex 1 ⁄
14 27
8⁄" - 16 UNC x 3" ⁄ ⁄" - 11 Heavy Hex 1 ⁄
14 27
10 ½" - 13 UNC x 3.5" ¾⁄" - 9 Heavy Hex 1 ⁄
19 36
12 ½" - 13 UNC x 3.5" ¾⁄" - 9 Heavy Hex 1 ⁄
19 36
I-795/906_17
REV_D

I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
INSTALLING THE 906 VALVE INTO AN HDPE
PIPING SYSTEM
WARNING
• Wear gloves while handling valve. Retainer
teeth are sharp and may cause injury.
• This valve is intended for use on plain-end
HDPE pipe and is NOT to be used on steel
pipe.
Failure to follow these instructions could result
in personal injury, joint leakage, and property
damage, and could void the product warranty.
1a. DO NOT REMOVE OR ADJUST THE ASSEMBLY HARDWARE:
Series 906 Installation-Ready™Knife Gate Valves are designed so
that the installer does not need to remove the assembly hardware for
installation. This design facilitates installation by allowing the installer to
directly insert a pipe end into each opening of the valve.
1b. REMOVE SLEEVE: Remove the cardboard sleeve from the valve
interior. NOTE: This cardboard sleeve will be used as a guide for
marking the pipe ends in step 4.
2. INSPECT PIPE ENDS: Ensure that the pipe ends are clean and free
from damage and scratches within 2½inches/64 mm from the ends. All
oil, grease, dirt, and cutting particles must be removed. Failure to do so
will result in difficult assembly and potential joint leakage.
3. INSPECT PIPE GASKETS: Check the pipe gaskets to ensure that
they are suitable for the intended service. The color code identifies the
gasket grade. Refer to Victaulic publication 05.01 in the G-100 General
Catalog for the color code chart.
CAUTION
• A compatible lubricant must be used to prevent the pipe gaskets
from pinching/tearing during installation.
• Pipe gaskets are designed for one-time use only. DO NOT
attempt to reuse pipe gaskets.
Failure to follow these instructions will cause gasket degradation,
resulting in joint leakage and property damage.
4. MARK PIPE: Using the cardboard sleeve and a paint stick, mark
each HDPE pipe end around the full circumference:
• 1 7/8 inches/48 mm for 2–3-inch pipe sizes
• 2 ¼inches/57 mm for 4–8-inch pipe sizes
This mark will be used for visual inspection to ensure that the HDPE
pipe is inserted properly in the valve. If a full circumferential mark
cannot be achieved, make at least four marks equally-spaced around
the circumference of each HDPE pipe end.
5. LUBRICATE PIPE END: Apply a thin coat of lubricant to the pipe
end from the end of the pipe to the paint mark made in step 4.
Lubricate each pipe end in accordance with the “Lubricant
Compatibility” table. Always consult with the pipe manufacturer for
lubricant compatibility requirements.
I-795/906_18
REV_D

I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
TABLE 1: LUBRICANT COMPATIBILITY
Lubricant
Compatibility
with Grade “T”
Nitrile Gaskets
Compatibility
with Grade “E”
EPDM Gaskets
Victaulic Lubricant,
Soap-Based Solutions, Glycerin,
Silicone Oil, or Silicone Release Agent
Good Good
Corn Oil, Soybean Oil,
Hydrocarbon-Based Oils,
or Petroleum-Based Greases
Good Not
Recommended
WARNING
• Keep hands away from the pipe ends and the
openings of the valve when attempting to insert
pipe ends into the valve.
Failure to follow this instruction could result in
personal injury.
5a. ASSEMBLE JOINT: Assemble the joint by inserting the marked
HDPE pipe end into each opening of the valve. The HDPE pipe ends
must be inserted into the valve until (1) contact with the seat occurs
AND (2) the marks on the HDPE pipe ends meets the edge of the valve
body, as shown above.
Inspect
5b. INSPECT SEAT: Each pipe end must be inserted into the valve until
contact with the seat occurs, as shown above. A visual check is required
to ensure that the seat meets the pipe ends.
5c. REMOVE ONLY THE SPACER BOLTS: There is one spacer bolt on
each bolt pad to maintain spacing between the bolt pads during shipping
and assembly. After inserting pipe, remove only the spacer bolts and the
attached warning tags before tightening the four nuts in step 6.
CAUTION
• Spacer bolts are designed to keep the valve’s housings at the
proper spacing during installation of the pipe ends.
• These spacer bolts must be removed prior to tightening the hex
nuts to bring the bolt pads into metal-to-metal contact. The
bolts will prevent proper tightening of the valve housings.
Failure to follow these instructions will cause damage to the valve
components. This may result in joint leakage or property damage,
and could void the product warranty.
NOTE: Do NOT discard the spacer bolts. Reinstall the spacer bolts
to finger-tight after valve installation is complete. If the valve must be
removed from the system, the spacer bolts will be necessary to separate
housings and maintain spacing (dimension "C", as defined in the
dimension tables found on pages 7–10) between the bolt pads during
storage, shipping, and reinstallation.
I-795/906_19
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I-795/906 / Installation-Ready™Knife Gate Valve / Installation and Maintenance Instructions
6. TIGHTEN NUTS: Tighten the hex nuts evenly by alternating sides in a
crossing pattern (as shown in the sequence above) until metal-to-metal
contact occurs at the bolt pads.
NOTE: It is important to tighten the hex nuts evenly by alternating sides
to prevent pinching of the pipe gaskets. An impact wrench or standard
socket wrench with a deep-well socket can be used to bring the bolt
pads into metal-to-metal contact. Refer to the “Series 906 Helpful
Information” and “Impact Wrench Usage Guidelines” sections.
WARNING
• Visual inspection of each joint is critical.
• Improperly assembled joints must be corrected before the
system is placed into service.
Failure to follow these instructions could cause joint failure,
resulting in serious personal injury and/or property damage.
GOOD
BAD
7. INSPECT PADS: Visually inspect the bolt pads at each joint to ensure
that metal-to-metal contact is achieved across the entire bolt pad
section.
I-795/906_20
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