YALE® FIGURE 500 & 500R

CLOSURE OPERATION AND

MAINTENANCE INSTRUCTIONS

IMPORTANT INFORMATION

Note to Supervisor:
Please share this information with your employees and
make sure they have received training on closures
prior to operation and/or maintenance.

/!\ WARNING: Do not attempt to open the closure while under

pressure. Failure to relieve all pressure will allow the contents to
escape forcefully and may cause severe injury or even death. Follow
all instructions below.

Closure Installation Instructions are included with each closure shipment. These
instructions are also available at www.rmenergy.com. Go to Pipeline and Transmission,
drop down to Pipeline Products, and then select Yale Quick Opening Closures. Or,
if preferred, contact the Customer Service Department at one of the following
locations:

IN THE U.S.
1-800-654-5603 or (281) 351-2222

IN CANADA
1-800-661-5659 or (780) 437-6316

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SECTION ONE: Opening the Closure
1. Bleed pressure from pipeline or vessel in a safe
manner. Failure to do so may lead to a violent
expulsion of pressure resulting in severe injury or
even death.

2. If the closure is equipped with a Pressure Alert

Valve (PAV), remove the PAV stem from the PAV
body. Screw the stem into the retainer on the cap. FIGURE3.No. 1
See FIGURE No. 1.

NOTE: The PAV is intended to warn the operator of residual pressure in the
pipeline or vessel. The PAV is NOT intended to be used to bleed
pressure from the pipeline or vessel.

/!\ WARNING: Unrelieved pressure can cause severe injury or even death. If
pressure bleeds from the PAV after the PAV stem has been
removed, DO NOT open the closure. Replace the stem in the
PAV body and tighten. Repeat Steps 1 & 2.

NOTE: A PAV is standard equipment on all 6” and larger closures and may be
purchased as an option on smaller sizes.

3. The closure has right-hand threads, which require unscrewing the cap in a
counter-clockwise direction to open. To break the seal, use a lug wrench or CAT
Tool, as illustrated in FIGURE No. 3 and FIGURE No. 5. DO NOT use a metal-
faced hammer to loosen the cap, as excessive hammering will significantly
deform the lugs as illustrated in FIGURE No. 4, and
may initiate a crack in the cap or hub.
Reference
NOTE: If excessive torque is required to break the Mark
seal, it may be an indication of unrelieved pressure.
Mark
4. After breaking the seal, unscrew the cap from the
hub. The cap should turn by hand with little or no
resistance. Do not use excessive force to open the cap.
FIGURE No. 2
5. Swing the cap free of the hub to gain access.

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 FIGURE No. 3 FIGURE No. 4

FIGURE No. 5 FIGURE No. 6

Proper Operating Position. WRONG Operating Position!

Always operate the closure from the NEVER operate the closure while
side as illustrated in FIGURE No. 5. standing in front of the cap as
illustrated in FIGURE No. 6.

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SECTION TWO: Closing the Closure

CAUTION: DO NOT overtighten the cap. Overtightening may result in damage to

the closure threads and seal areas.

Closures NOT equipped with a Closure Actuator Tool (CAT): The cap can be fully
tightened using the appropriate wrench. DO NOT use a metal-faced hammer to tighten
the cap, as excessive hammering will significantly deform the lugs, as illustrated in
FIGURE No. 4. It may also damage the closure threads and seal areas.

Closures equipped with a Closure Actuator Tool (CAT): The cap can be fully tightened
within the limits of the CAT tool. Do not use additional mechanical means, such as
cheater bars or cranes, to tighten the cap.

On closures with a Pressure Alert Valve (PAV), insert and tighten the PAV stem into the
PAV body on the hub.

CAUTION: The PAV is designed to be hand-tightened. DO NOT use excessive

force to tighten the PAV stem. Excessive torque may damage the PAV.

SECTION THREE: Initial Start-Up

1. Open the closure as instructed in Section One.

2. Remove the o-ring. Clean and lubricate the seal areas and threads of both the cap
and the hub. For most environments, a general purpose lithium grease or
equivalent works best. Do not use a silicone type lubricant. Tacky, high-
temperature grease is not recommended.

3. Closures NOT equipped with a CAT tool:

3.1 With the o-ring removed, tighten the cap until metal-to-metal contact is made
between the hub and cap seal surfaces. (This can be determined by observing
the cap movement. Stop tightening when the relative motion between the cap
and hub has ceased.)

3.2 Mark this position on the cap and hub for future reference, as illustrated in
FIGURE No. 1, to indicate the point at which the closure is fully closed.

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 3.3 Open the closure and replace the o-ring as instructed in Section Four. DO
NOT tighten the cap beyond the “Closed Position” reference point. Tightening
beyond this point can result in damage to the closure threads and seal areas.

4. Closures equipped WITH a CAT tool:

4.1 Inspect o-ring for damage and install as directed in Section Four.

4.2 Screw the cap onto the hub by hand until the cap stops.

4.3 Utilize the CAT tool to tighten the closure completely. Do not use excessive
force or additional mechanical means such as cheater bars or cranes.

4.4 Mark this position on the cap and hub for future reference, as illustrated in
FIGURE No. 1 & 2, to indicate the point at which the closure is fully closed.

SECTION FOUR: Maintenance

1. Every time the closure is opened, visually inspect the o-ring and the threads of the
cap and hub as instructed in Section Six. If tears, nicks, cuts or rough surfaces
appear on the o-ring, replace it with an o-ring supplied by R&M Energy Systems to
ensure the dimensional integrity.

2. Whenever foreign matter exists on the threads or seal areas, remove the o-ring and
clean the threads, seal areas and o-ring groove. Lubricate the threads and seal
areas with an anti-galling lubricant such as lithium grease. Do not use silicone type
lubricant. Do not apply lubricant to the o-ring groove prior to installing the o-ring.

3. If cracks are visible on the cap or hub, replace the component.

4. Clean the o-ring and apply a light coating of lubricant to it. Install the o-ring in the
groove.

5. Where applicable, using the grease fittings provided, thoroughly lubricate the cap
pin bushing and the hinge socket on hinged closures on a regular basis. It is
recommended the hinge socket be completely filled with grease.

6. Lubricate the seal areas and threads as described in Section 3.

7. Refer to Section 5-C for necessary adjustments to the hinge.

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SECTION FIVE: Disassembly and Adjustment of Closure

/!\ WARNING: Do not attempt to disassemble the closure while under pressure.
Failure to relieve all pressure may lead to a violent expulsion of the
contents. This may lead to severe injury or even death. Remove the
PAV stem from the valve body to assure all pressure has been
relieved and screw it into the retainer on the cap, as instructed in
Section One, Steps 1 & 2.

A. Disassembly of Horizontal Hinge Closure (Figure No. 7, 8, 11 & 12)

1. Use the appropriate wrench or Closure Actuator Tool (CAT) to break the seal.
Unscrew the cap from the hub.

2. On closures not equipped with a CAT tool: Lift the cap until the hinge arm clears
the hinge socket. (Figure No. 7 & 8)

3. On closures equipped with a CAT tool: Wrap a lifting strap around the bend of the
hinge elbow. (Figure No. 11 & 12)

3a. On closures equipped with a roller trolley, lift and pull the hinge elbow until the
roller clears the stop on the jib arm and remove. Carefully and slowly place the
cap face down on a clean, flat surface. (Plywood or a wood pallet is preferred.)

3b. On closures equipped with a dual wheel trolley, place an identifying mark (with a
marker, paint, etc.) on the adjustment bolt just above the hinge elbow, or
measure the distance from the bottom of the I-beam to the top of the hinge
elbow. Lift just enough to take the weight off the vee-nut block and remove the
adjustment nut and vee-nut block. Carefully and slowly lower until the hinge
elbow is free of the adjustment bolt and place the cap face down on a clean, flat
surface. (Plywood or a wood pallet is preferred.) Do not remove the dual wheel
trolley from the jib arm. Secure the trolley against the post of the jib arm with a
clamp to avoid unwanted movement and possible injury while handling.

3c. If the jib arm is removed from the hinge socket on sizes 20” and larger closures,
be careful not to damage the bronze bushing in the hinge socket or the lower
thrust bearing on the end of the jib arm.

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Reassembly of Horizontal Hinge Closure

1. Assure that mating parts and bearings are free of all dirt, sand and debris prior to
reassembly. On sizes 20” and larger, make sure all removable hinge parts (dust
cover, top bronze bushing, bottom bearing) are installed in their respective locations.
If removed during disassembly, insert the jib arm in the hinge socket and remove the
clamp used in Step 3b of the disassembly section.

2. On closures not equipped with a CAT tool, insert the hinge arm into the hinge socket
and proceed to Step 4.

3. On closures equipped with a CAT tool, wrap a lifting strap around the bend of the
hinge elbow.

3a. On closures equipped with a roller trolley, lift until the roller clears the stop on
the jib arm and slide on. Ease down until the roller rests on the jib arm and
remove the strap.

3b. On closures equipped with a dual wheel trolley, lift and carefully slide the hinge
elbow back onto the adjustment bolt, install the vee-nut block and the
adjustment nut. Tighten to the mark on the adjustment bolt made in Step 3b of
the disassembly section and remove the strap.

4. Thoroughly clean the cap and hub threads, sealing surfaces and o-ring groove. Lubricate the
cap and hub threads, sealing surfaces, and all grease fittings. Apply a light coating of
lubricant to the o-ring.

NOTE: Do not put lubricant in the o-ring groove prior to installing o-ring.

5. Begin screwing the cap onto the hub while checking vertical and parallel
adjustments. The cap should screw onto the hub without thread drag.

B. Disassembly of Vertical Hinge Closure (Figure No. 9, 10, 13 & 14)

1. Use the optional lug wrench or closure actuator tool (CAT) to break the seal.
Unscrew the cap from the hub.

2. On closures smaller than 16”, lift the cap until the davit arm clears the davit base
socket. (Figure No. 9 & 10)

3. On closures 16” and larger, attach the hooks of a hook sling in the holes of a
minimum of three (3) cap ribs. Carefully and slowly lift the cap until the davit arm is
out of the davit base socket. (Figure No. 13 & 14)

YCO&M December 2011 Page 7

NOTE: On sizes 26” and larger closures, be careful not to damage the bronze
bushing in the davit base socket and lower bearing on the end of the davit
arm. Removal of the dust cover from the davit arm is not necessary. Place
the cap face down on a clean, flat surface that will allow the davit arm to
hang free. (Wood pallets are preferred.)

Reassembly of Vertical Hinge Closure

1. Assure that mating parts and bearings are free of all dirt, sand and debris prior to
reassembly.

1a. On closures smaller than 16”, insert the davit arm into the davit base socket
until fully seated.

1b. On sizes 16” through 24” closures, lower the davit arm into the davit base
socket until fully seated. Position the dust cover against the davit base socket.

1c. On sizes 26” and larger closures, install the bronze bushing in the davit base
socket, if removed during Step 2 of the disassembly section, and carefully lower
the davit arm into the davit base socket until fully seated. Position the dust cover
against the davit base socket.

2. Thoroughly clean the cap and hub threads, sealing surfaces and o-ring groove.
Lubricate the cap and hub threads, sealing surfaces, and all grease fittings. Apply a
light coating of lubricant to the o-ring.

NOTE: Do not put lubricant in the o-ring groove prior to installing the o-ring.

3. Begin screwing the cap onto the hub while checking the vertical and lateral
adjustments. The cap should screw onto the hub without thread drag.

C. Adjustment of Cap Relative to Hub

1. Horizontal hinge 8” and smaller: (Figure No. 7)

1a. Vertical adjustment is made by loosening the set collar and moving it up or
down the hinge arm. Retighten the set collar against the hinge socket after
adjustment.

2. Horizontal hinge 10” through 14”: (Figure No. 8)

2a. Vertical adjustment is made by tightening or loosening the adjustment nut.

YCO&M December 2011 Page 8

3. Horizontal hinge 16” and larger: (Figure No. 11 & 12)

3a. Position the cap face approximately two (2) or three (3) inches from the hub
face. The cap face must be parallel to the hub face. This can be determined by
measuring the distance between the two faces at the top and bottom, or by
using a level. Adjustment is made by moving the hinge elbow laterally along the
cap pin after loosening one or the other of the two set collars. If the cap is
closer at the top, loosen the inside set collar and move the hinge elbow closer to
the cap. If the cap is closer at the bottom, loosen the outside set collar and
move it out and retighten. Then move the hinge elbow away from the cap.
After the adjustment, tighten both set collars against the hinge elbow.

CAUTION: Never leave the outer set collar loose. This makes it possible for the cap to
slide off the cap pin and drop free.

3b. Vertical adjustment is made by tightening or loosening the adjustment nut.

Properly adjusted, all the weight of the cap will remain on the hinge elbow and
jib arm without transferring any weight to the hub during the thread make-up,
thus preventing thread drag.

4. Vertical hinge 8” and smaller: (Figure No. 9)

4a. No adjustments should be necessary on these small closures.

5. Vertical hinge 10” through 24”: (Figure No. 10 & 13)

5a. The adjustment bolt is located on the bottom of the davit base socket. It adjusts
the height of the cap relative to the hub to minimize the thread drag while
operating the closure. If excessive thread drag is noticed while turning the cap,
adjust this bolt in small increments until minimum drag is obtained.

6. Vertical hinge 26” and larger: (Figure No. 14)

3a. Lateral Adjustment – Center the cap with the hub laterally using the adjusting
nuts on top of the davit arm adjustment sleeve. Make sure both nuts are tight
after completing the adjustment.

3b Vertical Adjustment – Loosen the set screw in front of the yoke assembly.
Slightly turn the nut on top clockwise to raise the cap, or counter clockwise to
lower the cap. Turn the cap to evaluate the thread drag and repeat as
necessary until minimum thread drag is obtained. Tighten the set screw after
the final adjustment.

YCO&M December 2011 Page 9

 Hinge Arm

Set Collar Adjustment Nut

Hinge Socket

FIGURE No. 7 FIGURE No. 8

Davit Arm

Davit Base Socket

Adjustment Bolt

FIGURE No. 9 FIGURE No. 10

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 FIGURE No. 11 FIGURE No. 12

FIGURE No. 13 FIGURE No. 14

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SECTION SIX: Thread Inspection
A thread gauge is available from R&M Energy Systems. It is a template containing
five different modified acme thread profiles. The gauge is intended to allow the
user to estimate the extent of wear or damage to the closure threads based on a
visual comparison of the thread form between the gauge and the closure
component.

Procedure for Thread Inspection:

Determine the profile that matches the threads on your closure and snugly insert the
gauge into the threads of the closure component. Make a visual comparison of the thread
profile to the gauge. Inspect both cap threads and hub threads for the following:
• Worn thread flanks
• Rounded thread crests
• Galling
• Excessive corrosion
• Deformed thread profiles
• Gouges or nicks
• Cracks, especially at the thread root radius

Additional Inspections:
Inspect the cap and hub for the following:
• Gouges, nicks or cracks in the seal area
• Excessive corrosion or wear in the seal area
• Excessive deformation of cap lugs resulting from hammering, etc.
• Cracks on the cap exterior

Important Considerations:
1) Equipment containing excessive wear, damage, or cracks should be replaced
immediately.
2) “Acceptable” wear is dependent upon the closure’s environmental conditions including
pressure, temperature, media, frequency of use, etc.
3) NDE, such as PT, MT, UT and RT, provides a suitable means for detecting cracks.
Contact your nearest customer service representative with any questions or concerns.

4 pitch 3 pitch
.096 X .133 High .128 X .187 High

R&M Energy Systems

.204 X .250 High
.204 X .231 High
2 pitch

YALE
2 pitch

Figure 500 Closure Threads

1 pitch
.455 X .375 High

Thread Gauge Proper Thread Gauge Fit

YCO&M December 2011 Page 12

 R&M Energy Systems
10906 FM 2920
Tomball, Texas, U.S.A. 77375
(800) 654-5603
(281) 351-2222
Fax: (281) 351-6557

E-mail: sales@rmenergy.com

R&M Energy Systems Canada

3703 98th Street
Edmonton, Alberta, Canada T6E 5N2
(800) 661-5659
(780) 437-6316
Fax: (780) 435-3074

YCO&M December 2011 Page 13