Tufline Sleeved Plug Valves We) inter itz Liles & Re erlyTrouble-free operation. Tufline® valves have proven them- selves with long-term, trouble-free service in a wide variety of applica tions. Properiy installed, adjusted, and operated, these valves should roquira minimum attention. Questions? It there are any questions, centact ‘your Xamox representative, Xomox Service Center, or the factory. Xomax Automation & Service Center addresses and phane numbers are listed on the back cover. ‘You may aiso contact the factory at 513-745-6000 Contents Page Important Information Field repair or factory repair? 2 Replacement parts 3 Maintenance Instructions General instructions forall valwes 2... 3 ‘Top Seal Replacement General instructions for all valves: eer) Repair Instructions 1/2 and i inch valves, and 1 inch ductile iron valves 6 1 through 8 inch valves, outotuina .. 2... 8 1 through 8 inch valves, ievling 13 10 and 12 inch valves, outatdine x 16 Service Centers... Back Cover Important Information Read carefully. ‘The following procedures and illus ‘ations have been prepared to assist you in the maintenance and repair of your Tutine valves, Please read these instructions carefully, READ INSTRUCTIONS BEFORE SERVICING VALVE. Failure to follow instructions could result in death or Serious injury. If there is any question. contact the factory at 513-745-6000, MASSIVE LEAKAGE. D0 NOT attempt to repair a valve or its accessories while pressurized! Death or serious injury could result NOTICE ‘These instructions have been prepared for valves as they are ‘currently manufactured. Ifyou have an older design valve that needs repair, contact either the factory or your nearest Service Center 10 make sure that you have the correct repair parts and instructions. Field repair or factory repair? PARTS DAMAGE. Customer assumes all responsibilty for valve performance on valves rebuilt in the fisid by non-Xomox personnel Warranty of renair parts is limited to replacement of parts due to defects in material and workmanship af the parts themselves. Proper installation of repair parts Plays an important role in their performance. Thase parts may be damaged if improper installation occurs, Field repair of valves may be: performed by carefully folowing the instructions in this book. However, this should be weighed against the advantages of returning valves to & Xomox Service Center for repair, ‘Because of the specialized equi ment available at service centers, repairs can often be performed more economically, even consider- Ing transportation costs, Further, factory and service center repaired valves are tested to the same specifications as new valves and carry the standard new valve waranty, Field repair of incline 10 and 12 inch valves is not recommended except by Xomox personnel, For informa tion an repair of these valves, consult one of the Xomax Service Centers listed on the back cover. cxygtxororcomcraton {509.al sph remevea Tle inate aed taderarhReplacement parts. Replacement parts are designed for maximum interchangeabilty between valve sizes, types and models. However, some are not interchangeable; and, ta ensure receiving correct parts, the folianing information must be supplied when ordering replacement parts, 1. Specity if repairs in-line or out- ofing on all 1/2 and 2/4 inch valves a8 well a8 1 inch ductile iron valves. 2. Specify valve identification number (six digit number found on hub washer ar flow indicator}. Hf you cannot supply the 1. number, provide the following Intarmation a, Size, 1b. Body and plug material 1, Class (150, 300, 600) ds valve for use on a toxic servico such as Chlorine or HF? tyes, spacity. 'e, Does valve have hex head bolts ‘or allen head adjustmant screws? if allen head, advise f aT" is stamped on the cover. 1s valve manual or actuated? It actuated, specily type of actuator. Tutline valves are designed and buill to give long, trouble-free service. Properly applied, adjusted and operated, these valves should require minimum attention, The following procedures and ils trations have been prepared to assist you in the maintenance and repair of your Tutiine valves. Please read instructions caretully. If there are any quastions, consult your Tufline valve representative oF the factory at 513-745-6000, Adjustments. Loss of seal. All Tufline valves are factory adjusted and normaly further adjustment is not required However, if seepage dos oocur at the plug stem of downstream, the following agjusiments can be mage Tighten each of the three adjust- ment bolts (ar serews} 1/4 turn. Gperate valve and check tar leak: age. Repeal as necessary to stop the seepage, “The need for frequent adjustment of the bolts, and/or many adjustment tums indicates the seals are wom to the point af needing replacement (see page 4), Excessive tightening Of the adjustment bolts wil cause er Increase in the valve stem torque. Siees (inetes) Valve torque. Valves should be operated under service conditions for at least twelve hours before any torque adjusi- ments are made, since the infil breakaway torque normally reduces with usage and temperature. Running torques. Normal running torques may be less than the values shown in the tables below Valve torque may be greater if the valve is used fo control a highly viscous or abrasive medium. UHMWPE shee Foat-Paunds. PTFE UHMWPE sleeve Foat Pounds. Foat-Paunos astm atstem EB Worm geart* "vaues ate plug canbe gemMASSIVE LEAKAGE, DO NOT atlempt to repair a vaive or its accessories while pressurized! Death or serious injury could result. Static Eliminator (8-4 inch only) Thasst Collar Motat Diaphragm Formed Diaphragm Assembly Cone Too! «6 (00 Plug (Not included cr) Qe Disassembly. MEDIA EXPOSURE. Depressurize, clean, and neutralize any media that may remain in the vatve and pipeline. If the valve is in the Pipeline, you must follow your line entry procedures. Always wear appropriate safety attire. Failure to follow this waming could result in death, personal injury, or property damage. Loosen the cover bolts (or nuts) approximately 4 tums each, being careful not to allow the release of the valve caver. Rotate tha plug 1/4 turn to release any trapped pressure within the valve. Remove the hub (or E.G. actuator and turacket) Remove the valve cover, Using @ wrench to tum the plug, remove the plug and top seal parts Top seal parts must be discarded. Inspection. See drawing below. For best sealing results inspect the following components: 1. Tha seal surface on the plug stem. 2. Tha plug surtace, 3. The seal surface on the cover. 4. The body seal suriace that mates with the cover. 5. Tha sleove. ‘Those surfaces should be free trom detects, which are typically caused by corrosion, erosion, improper handling, or improper storage of a disassembled valve, IW detects are found on any of these parts, the valve must not be repaired.Reassembly. 41. Replace the plug in the valve body with the ports in the open positian. 2. install wedge ring onto plug stem The small diameter end must be opward. 3, Place assembly cone too! with formed PTFE aphragm over plug stam, (In valves that nave a thread- @d stud atop the plug stem it wil be necessary ta make a 5/1B-inch diameter hole through the crown of the assembly cone lool to allow the cone ta rest on the top ofthe plug stem.) 4. Push the formed PTFE diaphragm over taper on assembly cone tao} and onto plug stem, being sute to evenly distribute the pushing force on the crown of the diaphragm to prevent lnack rolling and damage tothe sealing lip, When installing tne formed PTFE diaphragm, the thrust collar may be used 48 a pushing tool to push the diaphragm over the taper and onto the largest diametar of the assarnbly cone tool The thrust collar can now be set aside, Continue pushing the diaphragm ever assembly cone tool and anto plug stom 5, Check to see that the wedge ring has seated properly inside the ‘crown of the formed PTFE diaphragm, §. Remove and discard assembly ‘cane tool 7. Install metal diaphragm 8, Install the thrust collar with fat side facing up. 8. On ‘& through 4 inch valves, Install the static eliminator wit thin lip facing down. (Not required on actuated valves.) 10, Back out adjustment screws 10 within one thread of bottom of cover bore, 11. Install the cover. To facilitate Lightening of the cover Botts, press the plug into the body with an arbor press until the bottom of the plug port opening is 1/16 inch above the bottom of the walve body part open ing. Do not apply force to the cover 45 this may damage the foimed PTFE diaphragm 12. Check to see that the metal laphragm is centered in the valve body counterbore, Ka 13. Tighten the caver bolts alternately (criss-cross pattern) and incrementally unt the following torque values are reached: Bot Sica Aintes) Footounds VALVE DAMAGE, DO NOT exoged maximum forque values, Personal injury and property Gamage may result, 14, Tighten the agjusting bolts uni+ formiy In 1/4 turn increments until contact is mad, then tighten an additional 1/4 turn. 15, Replace the hub and wrench {or bracket and E.G. actuator) and rotate the plug. 16, Compare tha valve torque against the values listed under Running Torque on Page & It gatistactory results have not been obiained, consult the nearest Xomox Service Center,MASSIVE LEAKAGE. D0 NOT attempt to repair a valve or its acessories while pressurized! Death or serious injury equid result. MEDIA EXPOSURE. Depressurize, clean, and neutralize any media that may remain in the valve and pipeline. Ifthe valva is in the pipeline, you must follow your line entry procedures. Always wear appropriate safety attire. Failure to follow this warning could result in death, personel injury or property damage. Special tool Available from your Xamox Servioe Center Formed PTFE diapnragen Sized & taped slesve ‘Assembly cone tool Static eliminator Valve repair kit Do not remove tape from sleeve until ready for use. Do not remove formed PTFE diaphragm trom assembly cone took Before proceeding with valve repair, you must read pages 2 and 3 carefully. == ‘Typical valve ready for repair 1. Loasen cover bolts four turns each. Rotate the plug appraximate- ly 114 tun to release any trapped pressure within the valve. Remove the cover bolts. Lift plug: cover-handle assembly from valve. Remove handle retaining nut and disassemble washers, handle, and caver from the plug, Remove and discard the top seal parts from the plug.2. To remove the sieeve, cut through the sleeve with a sharp knife at top ‘and bottom side of the por. Care ‘must be taken not to score the valve body during sleeve removal Discard and replace valve body if scored. With a scored body, leakage may occur 9. After the sieeve has been cut ingort a sorevdriver behind the sieeve and curl the sleeve aviay from the valve body. Reiove the sleeve by prying it out of the bady. Discard Old sleeve. Clean the body. plug, and cover. Check all parts for erosion and replace if necessary (Check the finish of the sealing sur faces on the plug. Rleplace the plug if not smooth 4, The replacement sleeve has been sized and taped at the factory. Do Not remove the tape until weady for use. (Sleeve port openings have been Dré-drilled in kits far in-line repair. Remove the tape and insert tha sleeve in the valve body with the heavier wall saction of the sleeve toward the bottom of the valve, Note: On sleaves with vant holes, the vant holes must be positioned 90° from the port openings 5. Piace the sizing plug in the sleeve and press the sizing plug to the Bottom of the valve body. Remove the sizing plug, using a jackscrew if necessary, 6. When the sleave is in the body, the upstream and downstream ports must be crilad out, Use a standara rill, and drill out the ports in the sleeve by driling through the ports of the valve body. (This pertains only to sleeves not pre-driled.) 7. Thm the burre and exoass sleeve matarial fram the ports with @ sharp knife. Care must be taken not to mar the sealing area of the sleeve or lenkage may result Insert the standard plug with the ports in an open position. The top of the plug should drop within approximately 1/4 Inch of the coun: terbore. IF it does not, resize with the sizing plug. 8. Install the wedge ring onto alug stem, The small diameter end must bbe upward. Place assembly cone tool with formed PTFE diaphragm over plug slem9, Push the formed PTFE diaphragm aver taper on assembly cone too! and onto plug stem, being sure to evenly distribute the pushing force on the crown af the diaphragm to prevent back rolling and damage to the sealing lip. When instaling the formed PTFE diaphragm, the thrust collar may be Used as a pushing tool to push the ‘laphragm over the taper and onto the largest diameter of the assemply ‘cone 100 10, The thrust collar can now be set aside, Continue pushing the laphragm aver assembly cone tao! and onto plug stem, Check to see that the wedge ring has seaied properiy inside the crown of the formed PTFE diaphragm, Rlomove and discard assembly cone tool, Install metal diaphragm. 11. Install thrust collar with flat sure face facing up. Install static elimina- tor with thin lip facing down. (Not required on actuated valves.) 12. On the valve caver, back out adjusting screves fo within one: thread of bottom of caver bore. 13, install the cover. To facilitate tightening of the cover bolts, press the plug into the body with an arbor press until the bottom of the plug ort opening is 1/16 inch above the bottom of the valve body port open- ing, Do not apply force to the cover, as this may damage the formed PTFE diaphragm. Check to see that the metal diaphragm is centered in the valve body counterbore Tighten the cover baits altemately (criss-cross pattern) and incremen- tally until the following torque values are reached: Batt Sze | oot-pounde | fines | FootFounés | a a | VALVE DAMAGE. DO NOT exceed torque values. Personal injury and property damage may result 44. Tighten the adjustment screws uniformly in 1/4 tum inererents until contact is made; then tighten. an additional 1/4 turn, ‘Replace the handle, washars, and retaining nut. Rotate the plug and ‘compare the valve torque against the values listed under Running Torque on page 3 If satisfactory results have not been ‘obtained, consult your nearest Xomax Service Genter MASSIVE LEAKAGE, DO NOT attempt to repair a valve or its accessories while pressurizod! Death or serious injury could result.Sizing plug 1 Spreading ico! Plunger Loading ring Special tool Available from your Xemox Service Center. Formed PTFE oaghragr a mon aped sleeve Thrust collar Weetge ring ~ > © (1-4 inch valves) Metal dlaphrogm Valve repair kit Do not remove tape from sleeve until ready for use. [Do not remove formed PTFE diaphragm fram assembly cane tool Before proceeding with valve repair, you must read MEDIA EXPOSURE. Depressurize, | pages 2 and 3 carefully. clean, and neutralize any media that may remain in the valve and pipesine. If the vaive is in the pipeline, you must follow your line seciry procedures MASSIVE LEAKAGE. DO NOT attempt to repair a vaive or its acoassories while pressurized! Anways wear appropriate safety attire, Failure to follaw this warning ‘cauld result in death, personal injury, ar property damage Death or serious injury could result, 1. Loosen the caver batts (or nuts) four tums each, Rotate the plug ‘approximately 1/4 turn to release any trapped pressure within the valve, Remove the hub (or EG actuator and bracket). Remove the cover bolts. Remove cover, Remove plug and top seal parts by turing plug with a wrench Remove and discard the old top geal parts trom plug. 2. To remove the sieeve, cut through the sleeve with a sharp knife at tap and bottom side of the ports, Care must be taken not to sore the valve body during sigeve removal, MEDIALEAKAGE. Discard and replace vaive body if scored. With a scored bady, in-line leakage may occur10 3, Altor the sloeve has been cut, insert a screwdriver behing the sleeve and curl the sleeve away from the valve body. Remove the sleeve by prying it out of the body. Discard old sleave, Clean the body ‘and plug, Check parts for erosion ‘and replace if necessary. Check the finish of the sealing surfaces on the plug, Replace the plug If not smooth, 4, The replacement sieeve has: ‘been sized and taped at the factory, Do nat remove the tape until ready for use, Place the loading ring in the coun terbore of the valve body. Flemove the tape fram the sleeve. Insert the sleeve so that its ports ‘are 802 from being aligned with the waterway of the valve body, Press the sleeve throught the load- ing ring until the bottom of the sleeve fs past the top of the retain- ing lips of the valve body (1/16 inch \wide protruding metal rib that sur- rounds the valve port), Manually rotate the sleeve until the ports of the sleeve are aligned with the ports of the body. 5. Place the large end of the plunger on top of the sleeve. Press the sieeve into the valve body with fan arbor press. Reverse the plunger and use the small end of the plunger to press through the loading ring, Romove the plunger and loading ting 6. When the sieeve is in the body, use a screwdriver (or prybar) through the port of the valve to tuck the edge of the sieeve part behind the retaining lip of the valve body. Fepeat on the other port opening. 7. Tuck the bottom and top edgas of the sleeve port opening into position ‘behind the retaining lip of the valve body. It properly installed, the edges of the sieeve ports should now be in perfect alignment and locked behind the retaining lips of the body. Algo the bottom of the sieeve should be resting on the lower lado ‘of the body and the top of the sleeve should be tucked under the upper ledge of the body. 8. Insert the spreading too! Into the sieeve and pr68s to tha bottom of the valve. This presses the sieeve to tha valve body around the ports to prevent tearing of the sleeve dur- ing sizing9. Place the sizing plug into the valve body and press the sizing plug to the bottom of the walve, Remove the sizing plug, using a jackscraw it necessary. There may be a small excess of sleeve material around the ports which should be trimmed with a sharp knife, Do not mar the Sealing areas of the sleeve or leakage may resuil, 10, Insert the standard plug with the ports in the open position. The top of the plug should drop within approximately 1/4 inch of the bady counterbore, If it does not, resize with the sizing plug. 11, Install the wedge ring onto plug stem, The small diameter end should be upward. Place assembly cane too! with formed PTFE diaphragm over plug stem 12. Push the formed PTFE diaphragm over taper on cone and onto plug stem, being sure to evenly distribute the pushing force on the crown of the diaphragm to prevent back rolling and damage to the sealing lip. When installing the formed PTFE diaphragm, the thrust collar may be used as @ pushing tool fo push the diaphragm over the taper and onto the largest diameter of the assembly ccone tool, 13. The thst collar ean novr be set aside. Continue pushing the iaphragm over assembly cone toot and onta plug stem, Check to see that the wedge ring has seated property inside the crown of the formed PTFE diaphragm, Remove and discard assembly cone tool. Install metal diaphragm, 14. Install the theust collar with flat side facing up. On 1 inch through 4 inch valves, install the static elimina- tor with thin lip acing down. (Not required on actuated valves.) 15. On the valve cover, back adjust: ing bolts cut to within one thread of bottam of cover bore: 46. Install the cover. To facilitate tightening af the caver batts, press the plug into the body with an arbor press until the bottom of the:piug port opening is 1/16 neh above the bottom of the valve body port open- ing. (Do not apply force ta the cover, as this may damage the formed PTFE diaphvagm. n‘47, Check to sae that the metal diaphragm is centered in the valve body counterbore, Tighton the cover bolts alternately (criss-cross pattem) and incremen- tally until the following torque values are reached: Bolt Size ] {inchas) | Poet-Pounds: VALVE DAMAGE. DO NOT exceed torque values. Personal injury and property damage may result 18. Tighten the adjustment bolts uniformly in 178 turn increments until contact is made; then tighten an additional 174 turn. Roplace hub (or €.6. actuator and brackel). Rotate the plug and come pare the valve torque against the ‘values listed under Running Torque ‘on page 3, If satisfactory results have not been obtained, cansult your nearest Xomax Service Center, 12Locating toot Special tool ol fife Available from your Xamox Service Center. Spreading tact Metal diaphragm Valve repair kit MEDIA EXPOSURE. Depressurize, clean, and neutralize any media that may remain in the valve and pipeline| {tthe valve is in tha pipeline, you ‘must follow your line entry prace- dures. Ahways wear appropriate safaty attire. Failure ta follow this warning could rasul in death, personal injury or property damage. Formed PTFE digpévagm ‘Do nat remove tape from sieeve unt ready for use. (Do not remove formed PTFE diaphragm fram assembly cane tool Static eliminator (-4inch valves) Before proceeding with valve repair, you must read pages 2 and 3 carefully. MASSIVE LEAKAGE, DO NOT attempt to repair a valve or its accessories while pressurized! Death ar seriaus injury could result, Typical valve ready for repatr. 1. Loosen the cover lots (or nuts} four tums each. Rotate the plug approximately 1/4 tum to release any trapped pressure within the valve, Remove the hub or EG actuator and brackel. Remove the caver batts Remove the cover. Remove plug and top seal parts by turning plug ‘wi a wrench, Remave and discard the old top seal parts trom plug. 2. To remove the sleeve, cut through the sleeve with a sharp knife at the top and bottom side of the port. Gare should be taken not to score the body during sleeve removal. Discard and replace valve body if scored. With a scored body, in-line leakage may cocur. 134 3. Insert a seraweriver behind the sleave and curl the sleeve away from the valve body. On larger valves a pry bar may be used Remove the sleeve by prying it out ol the body. Discard the old sleeve (Clean the body and plug s Check parts for erosion and replace necessary, heck te finish on the seating sur faces of the plug. Replace the plug if nat smooth 4, The replacement sleeve has been sized and taped at the factory, Do nat remave the tape until ready for use, Place the loading ring in the coun terbore of the valve body. Flemove the tape fram the sleeve. Insert the sleeve se that Its parts are 90° fram being aligned with the waterway ports of the valve body, Pross the sieeve through the load. ing ting unt tha bottom of the sloove is past the top af the retain- ing lips of the valve body waterway pans (1/76 inch wide protruding ‘metal nib that surrounds the valve bady waterway ports. Manually rotate the sleeve until the ports of the sleeve are approximate- ly aligned with the ports of tha body. 5. Using two threaded rods-and a metal strap, make a press arrange: ‘ment over the top of the valve body. Place the plunger on top of the sleeve, Wiha porta-power unit, press the sieeve into the valve ogy, using the large diameter of the plunger, Reverse the plunger and use the small end of the plunger to peass through the loading ring, Remove the plunger and loading ring, 6. When the sleeve is in the body, insert the lovating tool, press firmly, and rotate it to position the edges af the sleeve behind the lips. You should be able to hear the sleeve “pop” inta place, as wall as fee! it ‘through ‘the: locating tool Ths sleave should now be in periect, slignment and the edges at the por should be against the body behing the lips. The battom of the sleeve should be resting on the lower ledge of the body, and the top of the Sleeve should be tucked under the upper ledge of the body. 7. Insert the spreading too! into the sleeve and press to the bottom ot the valve. This presses the sleeve to the valve body around the ports ‘to prevent tearing of the sleeve dur- ing sizing, 8. Place the sizing plug into the valve body. Using the parta power unit, press the sizing plug to the bottom of the bady. Remove the ‘sizing plug, using a jacksorew it neoassary. There may be a small ‘excess of PTFE around the pons ‘which should be trimmed with a sharp knife. MEDIA LEAKAGE, DO NOT mar the sealing avaas of tha sleeve, madia leakage may resulInsert the standard plug with the ports in the open position. The top of the plug should drop within approximately 1M inch of the body counterbere, It It does not, resize wath the sizing plug, 4 9. Install the wedge ring ento plug stem. The small diameter end should be upward, Place assembly cane tool with formed PTFE diaphragm aver plug stem 10. Push the formed PTFE diaphragm aver taper on assembly cone and onto plug stem, being sure to evenly distribute the pushing force:on the crown of the diaphragm to prevent back rolling and damage to the sealing lip When installing the formed PTFE diaphragm, the thrust collar may be used as @ pushing tool fo push the diaphragm over the taper and onto the largest dlameter of the assembly ‘ane to0l ‘11, The thrust collar can now be set aside. Continue pushing the siaphragm over assembly cone tool and onto plug stem. ‘Check to see that the wedge ring has seated properly inside the crown of the formed PTFE saphragm. Remove and discard assembly cone toa 12. Install the metal diaphragm. Install the thrust collar with the fiat side facing up (On 1 through 4 inch valves, install the static eliminator with thin lip fac+ ing down, {Not required on actuat- ed valves.) 18. On valve cover, back out adjust- {ng bolts to within one thread of bet- tom of cover bore. Install the cover. Te facilitate tightening of the cover bbotis, press the plug inta the body ‘with the porta power unit (Do not apply fores ta tha cover as this may damage the formed PTFE diaphragm. 414. Check to see thal the metal diaphragm is centered in the valve ‘body counterbore. 415. Tighten the cover bolts alter: nately (criss-cross pattern) and incrementally until the following torque values are reached! VALVE DAMAGE, DO NOT exceed torque values, Personel inury and property damage may result uniformly in 1/4 tuen increments until contact is made; then tighten an additional 1/4 turn, Replace hub (ar EG acwater and bracket). Flotate the plug and com- pare the valve torque against the values listed under Running Torques on page 3, It satisfactory results have nat been obtained, consult your nearest omox Service Center, 15Repair Instruction iz'inch Valves ( Locating too! ‘Spreading too! Sizing pug Loading ring Plunger Required special tools Sized & taped sleave a ‘Assembly cone-foo! raunettrconpren ab rwoscoter D> Metatelepnragm Valve repair kit Do not remove tape from sieeve until ready for use, Do not remave formed PTFE diaphragm from assembly cone tool Before proceeding with valve repair, you must read pages 2 and 3 carefully. MEDIA EXPOSURE, Depressurize, ‘clean, and neutralize any media thet may remain in the valve and pipeline It the valve is in the pipeline, you must follow your line entry proce: dures. Always wear appropriate safety alti Failure to fallow this warming could result in death, personal injury, or property damage, MASSIVE LEAKAGE, DO NOT attempt to repair a valve or ts accessories while pressurized! Death or serious injury could result. Typical valve ready for repair ia 1. Loosen cover nuts four turns each. Rotate the plug approximate- ly 1/4 tum to release any trapped pressure within the valve. Remove the cover nuts. Remove gear assembly by remov- ing the four flange bolts. Remove compensator and cover from the valve, ae 2. Using a crowbar through the waterway of the valve body, raisethe plug by pressing up on the inside of the plug, From the top of the valve @ crowbar can then be Used to remove the plug from the valve body. Remove and discard the old top seal parts, 3. To ramave tha sleeve, cut ough it with a sharp instrument at the top and bottom side of the port, Care should be taken not to score the body during sleeve removal. MEDIA LEAKAGE. Discard and replace vaive body if soared. With a scared bedy, in-line leakage may occur 4, After the sleeve has been cut, Ingen a serewdrwver behing the sleeve and cull the slenve away from the valve body, Remove the sieeve by prying it out of the valve body, Discard the old sleeve, Clean the body and plug, Check paris for erosion and replace it necessary. Check the finish on the sealing sur- faces of the plug. Replace the plug it not smooth. 5. The replacement sleeve has been sized and taped al the factory. ‘Do hot remove the tape until ready tor use. Place the loading ring in the coun. terbore of the vaive body. Remove the tape trom the sleave. Insert the sleeve in the loading ring 50 that its ports are offset approxi- mately 1/4 Ineh from perfect align- ment with the valve body ports, 6, Pisce the plunger an top of the sleeve. Drive the plunger through the loading ring using 4 maltet, Remove the plunger and loading ring, 7. Place the locating too! in the waterway of the valve body with the formed end against the inside: port af the sleeve, and the opposite end braced agains! the side of the valve tbody port the hand pump, expand the locating too! until the edges of the sleeve are positioned behind the retaining lips in the body (1/16 inch ‘wide protruding metal rib that sur rounds the valve body ports), Repeat this procedure along the length of the por Repeat complete recess on other port The sieeve should now be in pertact alignment and its edges at the ports should be against the valve body and locked behind the lips ‘The bottom of the sleeve should rest on the lower ladge of the body, and the top of the sleeve should be tucked under the upper ledge of the body, 79. Place the spreading tool in the bottom of the valve under the ports. Expand the spreading tool with the hand pump, pressing the sieeve into the valve body beneath the ports. 10. Place the sizing plug into the valve body and press the sizing plug to the bottom of the valve. For ease of insertion, the sizing plug may be sprayed with a silicone lubricant LUBRICATION. Lubricants should NOT be used ifthe valve is in some specialized serviees such as chlo- fing, fluorine, oxygen, and food, lemove the sizing plug. using a Jackscrew if necessary. 8 11. Excess sieeve material should be trimmed with a knife around the ports and at the top of the sleeve. MEDIA LEAKAGE. D0 NOT mar the sealing areas of the sleeve. media leakage may result 12, insert the standard plug in the valve with the ports in open posi- tian, ‘The top al the plug should drop within approximately 1/2 inch of the body counterbore. Iitdoes not, resize with the sizing plug. 13. Install the wedge ring onto piug ‘stom. The small diameter end ‘should be upward, Place: assembly cone tool with formed PTFE diaphragm over plug stem, 14, Push the formed PTFE diaphragm over taper on assembly ‘cone tool and anto plug stem, being sure to evenly distribute the pushing fore on the crown of the diaphragm 4o prevent back ralling and damage to the sealing lip ‘When installing the formed PTFE diaphragm, the thrust collar may be ‘used as @ pushing {ool to push the diaphragm over the taper and onto the largest dlamater of the assembly ‘cone tool 16. The thrust callar can now be set aside. Continue pushing the diaphragm over assembly cone too! ‘and onto plug stem. ‘Cheok to see that the wedge ring hhas seated property inside the ‘crown of the formed PTFE diaphragm, Remove and discard assembly cone tool16. install the metal diaphragm. Install the thrust coltar with the flat surface facing up. Adjusting bolts in caver should be ‘backed Out fo within one thread of hnottom of cover bore 17. Install the cover. To facilitate tightening of the cover bolts, prass ‘the plug into the bady with an arbor press until the bottom af the plug port opening Is 1/16 inch abave the ‘bottom of the valve body port ‘opening. Do not apply force to the cover as this may damage the formed PTFE sdlaphragm 18, Check to see that the metal diaphragm is centered in the valve body counterbore, 19, Tighten the cover bots uniformly and alternately (in the order Indicated in the drawing in the following column) incrementally until 190 ft-lbs. torque is reached VALVE DAMAGE, DO NOT exceed torque requirement, Personal injury and property damage may result. 20, Tighten the adjustment bolts Uniformly in 1/4 turn inerements until contact is made: then tighten an additional 1/4 tur, 21. Replace the compensator and the EG assembly, Rotate the plug and compare the valve torque against the values listed under Funning Tarqua on page If satisfactory results have not been ‘obtained, consult yaur nearest Xomox Service Center, Product responsibility. Xomax's concern for product pertor- mange extends to the product's period of service. We feel itis important for users ta also be aware of their responsibilities. Our prod: Uuets are manufactured and used in numerous applications with a vide variety of service conditions, While general guidelines are often fur- nished, it obviously is not possible ta provide complete and specific Performance data for every concelv- ‘able service condition. Tharetora, the end user must assume final responsibility for proper evaluation, ‘application and performances of all products, The contents of this document are ‘presented for information purposes ‘only. Every otfort has bean made to ‘ensure accuracy. This information is ‘ot intended to be construed as Warrantige of guarantees, expressed Cr implied, nor imply use applicabili- ty, far products oF services described herein, We reserve the right to moaity or imprave the designs and specifica: tions of such products at any time without notice. “As the manufacturer, Xomox sells Its products and ser- vices pursuant ta its standard terms and conditions of sale, including its limited warranty, copies af which are available upon request. Xomox limits its liability specifically to the replacement or repair of ofective items, or ta @ refund for same. Xomox does not accept lability for any ineidental or conse quential damages, 9