Assembly
1. Secure the valve body in a vise or other fixed position with the valve pocket facing up.
2. Clean and visually inspect all new and used parts. Make sure all dirt, rust and old grease is
removed prior to assembly.
3. Lubricate the plug seal glands of the valve/adjusting nut with grease and install the plug seals
(8)
with the metal backup ring adja-
cent to the seal glands and facing away from the valve cavity.
4. Install the o-ring
(14)
onto the adjusting nut.
5. Apply a thin film of plug valve grease onto the primary sealing surface of the inserts (13) and install onto the adjusting nut.
*Split
inserts are installed after the plug is inserted into the adjusting nut.
6. Apply a thin film of plug valve grease onto the large diameter of the plug
(11)
and carefully insert the lower end of the plug, opposite
the hex/keyway, down through the inserts
(13)
until it seats into the adjusting nut.
*When using split inserts, the plug is seated into
the adjusting nut first. The inserts are then evenly spaced around the plug, hooking onto the adjusting nut.
7. Install the insert o-rings
(12)
by pressing them into the grooves of the inserts
(13)
with plug valve grease.
8. Tilt the subassembly and install the bottom capscrew
(15)
and washers
(2)(3)
through the bottom of the adjusting nut and into the
plug
(11)
.
*When using a GreaSeal® plug, the capscrew is replaced by a SafeTap® grease fitting and a 3/4” flat washer.
9. Apply anti-seize compound to the adjusting nut
threads and o-ring area and lubricate the valve pocket below the threads with all-
purpose grease.
11. Install the plug (
11)
, inserts
(13)
, and adjusting nut assembly into the valve body. Make sure that the roll pins
(9)(10)
in the body
are aligned with the slots of the inserts as you screw the subassembly into the adjusting nut.
12. Screw in the adjusting nut until proper alignment is obtained between the valve bore and the insert and plug. Do not tighten beyond
proper alignment. If sight through the bore is not possible, then screw in the adjusting nut until no more than one half of a thread or
no threads are visible.
13. Install the SafeTap
®
grease fitting
(7)
into the valve body plug using 50-60 ft-lbs of
torque.
Teflon tape should not be used with SafeTap grease fittings since they do not
seal on the threads.
See back page for more details on the SafeTap® grease fitting.
14. Install the stop bolt
(6)
and stop collar
(5)
if required.
15. Install the handle
(4)
, top capscrew
(1)
, and washers
(2)(3)
onto the top of the valve.
If
the valve has an actuator or gear operator, bolt it back on the valve body and verify full
90° rotation. Adjust limit stops as necessary.
16.
Remove excess grease from the valve bore and inspect plug alignment. Adjust as neces-
sary with adjusting nut.
17.
Grease the valve in the open position to approximately 3000psi, cycle once, and then
grease one more time. GreaSeal
®
plugs should be greased in the open position to pack
the valve cavity but may also be greased in the closed position prior to testing or while in
service.
See back page for more details on GreaSeal® plugs.
Repair Guide - LT Plug Valve
LT Valve Parts List