Repair Kits Available By Part Number Section 2 Page - GAMECO

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, poppet and seat retainer by re-using
the original seat disc screws. Apply a thin layer of thread locking
compound to the screw threads and torgue to 250-300 in/lbs.
2. Lubricate and install the new stem o-ring into the groove at the base
of the upper stem threads. Slide a new molded stem seal onto the
upper stem. Place the excess flow spring and poppet back over
the lubricated lower stem and slide the poppet over the lower stem
until the wrench flats of the lower stem are exposed. Using a screw
driver and crescent wrench, assemble the upper and lower stem
halves together. Use a thin film of thread locking compound on the
stem threads making sure that the threads are not contaminated
with grease.
3. Slide the stem/poppet assembly into the valve body.
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. Place the return spring over the stem seat.
2. Place the bonnet over the stem and compress the return spring
until the bonnet is flush with the valve body. Install two (2) bonnet
screws finger tight at locations opposite of each other. DO NOT
RELEASE THE BONNET UNLESS IT IS FLUSH WITH THE VALVE
BODY AND HELD IN PLACE BY AT LEAST 2 SCREWS THAT ARE
OPPOSITE OF EACH OTHER. Install the remaining six (6) screws
and torgue all eight (8) screws to 115-130 in/lbs.
3. Place the strainer back on the valve. Place the strainer top over the
strainer and secure with the two strainer screws with 50-60 in/lbs
of torque
4. Assemble the new upper flange seal gasket and new lower flange
seal gasket to the valve body. This should be done just prior to the
valve installation.Torque down to 115-130 in/lbs.
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".
8. Assemble the cotter pin into the pivot pin hole. Spread and turn
back the cotter pin legs around the pivot pin shaft.
9. Bench test the actuating mechanism by applying 0 to 35 psig air
pressure to the actuator two or three times while checking for binding
or interference. Be sure it operates smoothly and freely.
Test Procedures
1. Open and close the valve three or four times. Check for smooth
operation and proper opening and closing of the main seat (1 1 /8"
nominal opening). See caution note in test #2.
2. If the manual actuator is used, the release lever should snap back