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.

IMO-210EN 3

1 GENERAL 3. Remove or protect the handle or actuator from weld

splatter or arc strikes.
This instruction manual contains important information
regarding the installation, operation and troubleshooting 4. Weld by applying a recommended 1/8" (3.2 mm) max.
for the Jamesbury 1/2" – 2" (DN 15 – 50) Standard Bore, 1/2" weld bead per pass around each end cap. CAUTION:
– 1-1/2" (DN 15 – 40) Full Bore Series 4000 Model B 3- DO NOT heat the center section over 350˚F (176.7˚C).
Piece Ball Valves with ISO Bonnet. Please read the instruc- Use a temperature stick and a wet cloth wrapped
tions carefully and save them for future reference. 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
1.1 WARNING body temperature.
FOR YOUR SAFETY, TAKE THE FOLLOWING PRECAUTIONS BEFORE
REMOVING THE VALVE FROM THE LINE, OR BEFORE ANY DISASSEM- 6. After sufficient cooling of the valve, replace the handle
BLY. or actuator.

1. DURING REMOVAL AND DISASSEMBLY, WEAR ANY PROTECTIVE IMPORTANT: If the body seals (6) and (18) are removed for
EQUIPMENT NORMALLY REQUIRED TO PROTECT AGAINST DIS- welding, DO NOT REUSE THEM. When reassembling the
CHARGE OF TRAPPED FLUID.
valve, put new seals back into the grooves. Body seal kits
2. DEPRESSURIZE THE LINE AND VALVE AS FOLLOWS: are provided in (Table 5). Tighten the body bolts to the
torques listed in (Table 1).
A. PLACE THE VALVE IN THE OPEN POSITION AND DRAIN THE
LINE.
TABLE 1
B. CYCLE THE VALVE TO RELIEVE RESIDUAL PRESSURE IN THE Body Bolt / Hex. Nut Torque
BODY CAVITY BEFORE REMOVAL FROM THE LINE. Valve Size
Torque FT•LBS Torque N•m
Full Port Size In ( )
C. AFTER REMOVAL, AND BEFORE ANY DISASSEMBLY, CYCLE THE 1/2" (1/2")
VALVE AGAIN SEVERAL TIMES. 10 13
DN 15 (DN 15)
3. SEAT AND BODY RATINGS - THE PRACTICAL AND SAFE USE OF 3/4"
14 19
THIS PRODUCT IS DETERMINED BY BOTH THE SEAT AND BODY DN 20
RATING. READ THE NAME TAG AND CHECK BOTH RATINGS. THIS
1" & 1-1/4" (3/4" & 1")
PRODUCT IS AVAILABLE WITH A VARIETY OF SEAT MATERIALS. 26 35
SOME OF THE SEAT MATERIALS HAVE PRESSURE RATINGS THAT DN 25 & 32 (DN 20 & 25)
ARE LESS THAN THE BODY RATINGS. ALL OF THE BODY AND 1-1/2" & 2" (1-1/4" & 1-1/2")
SEAT RATINGS ARE DEPENDENT ON VALVE TYPE AND SIZE, 63 85
DN 40 & 50 (DN 32 & 40)
SEAT MATERIAL AND TEMPERATURE. DO NOT EXCEED THESE
RATINGS.
CAUTION: IF THE VALVE IS BEING DISASSEMBLED FOR
NOTE: OPTIONAL ROUND AND OVAL HANDLES ARE AVAILABLE FOR
THESE VALVES IN PLACE OF LEVER HANDLES. WELDING, DO NOT CUT OR SCRATCH THE SEATS, SEALS
AND SEALING SURFACES. DAMAGE TO THE SEALING
SURFACES MAY CAUSE LEAKAGE.

2 INSTALLATION After valve is in line,or before any testing,tighten compression

plate hex. head cap screws according to the MAINTENANCE
Screwed End Style - Use standard piping practices to Section below.
install valves with threaded end caps. When tightening
valve to pipe, apply wrench to end cap nearest the pipe 3 MAINTENANCE
being worked.
Routine maintenance consists of tightening the compression
Weld End Style - Only valves with UHMWPE or Delrin® plate hex. head cap screws periodically to compensate for
seats must be disassembled before welding in line. A the wear caused by the stem turning against the stem seals.
warning tag and replacement body seals are affixed to Check to make sure that the compression plate hex. head
valves with these seat materials. VALVES WITH OTHER SEAT cap screws are tightened to the torque listed in (Table 2).
MATERIALS SHOULD BE WELDED IN-LINE FULLY ASSEMBLED. Overhaul maintenance consists of replacing seats and seals.
A standard service kit consisting of these parts may be
1. Only a qualified person should weld, as outlined in obtained from your Jamesbury Distributor (see Table 4).
Section IX of the ASME Boiler Construction Code.

2. Cycle the valve to the fully open position.

4 IMO-210EN

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

Figure 1 Figure 2
IMO-210EN 5

FIRE-TESTED
Surface A

NON FIRE-TESTED

1/16" (1.6 mm)

Interlock

Figure 3

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

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

5
6
18
13 2
7
13
22
52
4 24

23

Figure 4
IMO-210EN 7

TABLE 4
Service Kits Valve Size – Full Port Size Shown in ( )

1/2" (1/2") 3/4" 1" (3/4") 1-1/4" (1") 1-1/2" (1-1/4") 2" (1-1/2")
Valve Size
DN 15 (DN 15) DN 20 DN 25 (DN 20) DN 32 (DN 25) DN 40 (DN 32) 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 ( )

1/2" (1/2") 3/4" 1" (3/4") 1-1/4" (1") 1-1/2" (1-1/4") 2" (1-1/2")
Valve Size
DN 15 (DN 15) DN 20 DN 25 (DN 20) DN 32 (DN 25) DN 40 (DN 32) 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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