Repair Kits Available By Part Number Section 2 Page - GAMECO

7. Check the poppet, disc seal retainer and seat ring for excessive
wear and damage. Replace if necessary with part number A3219-
15 for the poppet. A3219-3 for the disc seal retainer and A3219-
2 for the seat ring.
Valve Reassembly
NOTE: Clean all parts prior to reassembly. When lubrication is required,
use compound 11550-215 found in the enclosed kit, number 5555GP
(hydrolith grease). Apply all lubricant as a thin film.
Roller Actuator Subassembly
1. Lubricate the roller pin.
2. Assemble the roller pin into the roller actuator through the roller and
secure with a new cotter pin.
3. Set assembly aside.
Seal Gland/Stem Subassembly
1. Lubricate new outer stem bearing and new stem o-ring and
assemble into seal gland.
2. Lubricate new dirt seal and press fit in place into seal gland.
3. Lubricate the stem and carefully insert it, tapped end out, through
the seal gland assembly. Do not use excessive force that will cut the
o-ring or dirt seal.
4. Lubricate the three (3) new stem seal rings, new stem jam ring and
stem washer. Assemble these one piece at a time over the stem and
into the seal gland. Be careful not to damage any pieces on the flat
edges of the stem.
5. Set assembly aside.
Disc Holder Subassembly
1. Assemble new main seat disc and new poppet seat disc onto the
disc seal retainer. Be sure the wording “seat side” on the main seat
disc is facing down and the wording “seat side” on the poppet seat
disc is facing up.
2. Assemble the disc holder to the disc seal retainer assembly with the
four (4) disc holder screws. Torque down to 250-300 in/lbs.
3. Lubricate the inside bore of the disc holder and assemble the
poppet, excess flow spring and spring retainer into the disc holder.
The end of the poppet should be guided through the disc seal
retainer.
4. Compress these items into the disc holder and secure by reinstalling
the retaining ring.
5. Set assembly aside.
Stem/Actuator Assembly
1. Lubricate new inner stem bearing and new poppet bearing. Install
in valve body.
2. Install seal gland spring and new seal gland gasket into valve body.
3. Lubricate threads of seal gland. Carefully install the seal gland/stem
sub-assembly into the valve body and through the inner stem
bearing, engaging the seal gland gasket. Torque the seal gland
down to 800-1000 in/lbs.
4. Lubricate the face of the roller actuator assembly.
5. Assemble the lockwasher and jam nut onto the threaded end of the
jam pin. Do not run the nut up the thread at this point.
6. Lubricate the jam pin and slide it up into the roller actuator assembly.
Orient flat of jam pin with bore of roller actuator. While pushing up
on the jam pin, assemble the roller actuator assembly onto the stem
on the inside of the valve body. Align the flat of the jam pin with the
flat of the stem. The jam pin will drop down when properly aligned.
Once aligned, torque the jam nut down to 160-180 in/lbs. Secure
with a new cotter pin.
7. Check to see that the stem rotates smoothly by turning the roller
actuator.
Bonnet Assembly
1. Install new seat seal o-ring and seat ring onto the valve body.
2. Install the disc holder assembly onto the valve body, being sure to
guide the poppet through the poppet bearing. Assemble poppet
spring into the opening of the disc holder.
3. Lubricate the inside bore of the bonnet. Place the bonnet over the
poppet spring and disc holder assembly. Orient the screw holes in
the bonnet with those in the body so that the disc holder screws are
between the bonnet legs.
4. Press down on the bonnet and install the eight (8) bonnet scews.
Torque down to 115-130 in/lbs.
5. Assemble the strainer and strainer top to the valve. Secure with the
strainer washer and strainer screw. Torque down to 50-60 in/lbs.
6. Assemble the new upper flange seal o-ring and new lower flange
seal o-ring to the valve body. This should be done just prior to the
valve installation.
Manual/ Pneumatic Actuator Reassembly
Manual Actuator Assembly
1. Lubricate the pivot pin. Assemble the channel to the release lever by
pushing the pivot pin up through both pieces and placing the
washer between the top of the channel and release lever. Hold the
pivot pin hex and torque down the new pivot pin locknut to 115-130
in/lbs. Be sure the release lever pivots freely.
2. Assemble the collar washer and collar onto the end of the stem.
3. Assemble the channel spacer/release lever assembly onto the valve
body with the two (2) channel screws and two (2) lockwashers.
Torque down to 250-280 in/lbs. Align parallel to edges of the valve
body face before torquing down. Lever movement should not hit the
collar on the stem.
4. Install the new lever release spring in the recesses between the valve
body and release lever.
5. If a new fuse assembly is necessary, order part number A3219-35.
Torque it down to 240-300 in/lbs. into the channel spacer.
6. Install new bumper and new stop screw into the handle. Torque the
stop screw down to 250-280 in/lbs.
7. Assemble the lockwasher and jam nut onto the threaded end of the
jam pin. Do not run the nut up the thread at this point.
8. Lubricate the jam pin and slide it up into the handle. Orient flat of jam
pin with bore of handle. While pushing up on the jam pin, assemble
the handle onto the stem. Align the flat of the jam pin with the flat of
the stem. The jam pin will drop down when properly aligned. Once
aligned, torque the jam nut down to 160-180 in/lbs. Secure with a
new cotter pin.
Pneumatic Actuator Assembly
1. Attach the bracket with actuator to the valve body with the two (2)
bracket screws and lockwashers. Torque down to 250 in/lbs.
2. Assemble the collar washer and collar onto the stem.
3. Lubricate the jam pin and all the openings in the crank arm.
Assemble the jam pin into the crank arm, small end to the top, and
align so that the 5 /8" diameter crank arm hole is unobstructed.
4. Assemble crank arm onto the valve stem and rotate it clockwise so
that the crank arm leg clears the clevis legs. Push assembly onto
stem until contact is made with the collar. Rotate the crank arm
counterclockwise so the leg positions itself between the legs of the
clevis. Be sure holes are in alignment.
5. Using the end of a pencil or the equivalent, push down on the jam
pin from the top of the crank arm to engage its flat with the valve stem
flat. The jam pin should drop approximately 5 /8". Move or wriggle the
crank arm slightly while pushing down on the jam pin to help assure
proper alignment.
6. Assemble the jam nut fully onto the jam screw. Assemble the jam
screw into the crank arm and torque down to 200 in/lbs. Turn and
torque down the jam nut.
7. Assemble the two pivot pin washers onto the pivot pin. Lubricate the
pivot pin shaft and assemble through the holes of the clevis legs and
crank arm leg. The air chamber shaft can be displaced manually
along with movement of the crank arm to effect alignment. Once the
pivot pin is engaged, check the top surface of the crank arm in
relationship to the top edge of the valve face, or to a horizontal, so
viewed from the end of the valve stem. The crank arm top surface
should be at a slight angle to the left, as if rotated counterclockwise
from the horizontal, approximately two to three degrees. Measure
the clearance between the collar and end of the poppet through the
outlet of the valve. It should measure 3 /32" ± 1 /64".