6 IMO-R27
4.4 Assembly
It is advisable to replace seats and seals if complete
disassembly and reassembly becomes necessary. Refer to
the Service Kit chart (see
Table 1
). A good lubricant
compatible with the tank car commodity MUST be applied
to the insert threads to prevent galling during assembly.
1. Clean all valve components if not done previously.
2.
Re-inspect all components for damage before
reassembling the valve. Look for damage to the
seating areas, stem, body and body cap; and look for
wear in the bearing areas. Replace any damaged parts.
3. Carefully clean and polish the ball (3) sealing surface. It
should be free of all scratches and grooves.
4. If the ball is slightly damaged, it may be possible to
smooth the sealing surface with crocus cloth or
equivalent. If deep scratches are present, replace the
ball.
5. Secure body (1) with body joint opening facing up.
6. Slide one valve seat (7) sideways into the body (1) to
below the stem bore, and tilt it into place so that the
proper surface (see
Figure 3
) will be adjacent to the
ball (3), being careful not to cut or scratch the seat.
7. For Fire-tite®, Place the stem bearings (70) and
secondary stem seal (71) as shown in
Figure 4
on the
stem. For non
Fire-tite
place the stem bearing (70) on
the stem. See How to Order Section to determine
proper valve construction.
8. Insert the stem (5), through the insert end of the body,
being careful not to scratch the stem sealing surface;
and press it gently up into the stem bore until
resistance is felt from the stem bearing. Holding the
stem in place from the bottom, insert the stem seals
(69) over the stem (5). (see
Figure 5
for proper V-ring
and graphite seal orientation).
9. Place the compression plate (10) over the studs (14).
Place one stop bushing (39) over each stud (14).
10. Place a stud lock nut (18) on each stud (14) and
tighten nuts alternatively so that the compression
plate (10) remains parallel with the body. Tighten
down the nuts until the stem seals/v-ring set is fully
seated, then tighten the nuts and additional 1/4 turn. If
necessary, retighten the stud nuts (18) until the plate is
level.
NOTE:
Check all fastener threads for damage. Ensure
fasteners are not bent or deformed. Assure nuts can be
assembled the full length of the fastener with no more
than finger tight force. Fastener grade markings must be
visible after assembly.
11. Screw the insert (2) into the body until it is fully seats,
and then mark its position as shown in
Figure 6
.
Counting the number of turns, remove the insert.
12. Place the valve in a vertical position, body joint up, on
a clean soft surface such as a folded rag or piece of
cardboard. Insert bottom grounding spring (36) into
the hole at the bottom of the stem (5). Insert the ball
(3) rotating it onto the stem (5) in the closed position.
If necessary, turn the stem blade to align with the ball
slot. Make certain that the stem blade is in the middle
of the ball slot; i.e. equal distance from the ends of the
slot. Rotate the ball if necessary (see
Figure 3
).
13. Place the second seat (7) into the insert (2) with the
proper surface adjacent to the ball (see
Figure 3
).
Stem must be cenetered in
ball slot as shown at assembly.
Seats must be in this
position at assembly
WARNING:
IF THE COMPRESSION PLATE IS NOT LEVEL AND PARALLEL TO THE
BODY, AN UNEVEN LOAD IS APPLIED TO THE STEM SEALS AND MAY
RESULT IN LEAKAGE AND PREMATURE WEAR.
Figure 3 Proper Seat and Ball Orientation
Figure 4 Stem Bearing Orientations
Figure 5 Stem Seal Orientation
FIRE-TITE
NON
-FIRE-TITE
V-RING
STEM SEALS
GRAPHITE
STEM SEALS
