Flowserve G4 Marathon Sleeveline Plug Valves - Manual (Page 10)

10
Flow Control Division
Section 1.0
Due to the tooling and associated equipment required
(presses, fixtures, etc.) to rebuild 10"-14" size valves, it is highly
recommended they be returned to the factory or a Flowserve
Authorized Black Tie Valve Rebuilder for repair and rebuild.
Many valves made by Flowserve Corporation handle corrosive
chemicals which may be injurious to property or personnel.
Valves returned without proper attention given to the safety
requirements will be shipped back to the consignor collect.
Note: Part number reference is shown in Figure V B-9.
1. Apply Durco Seal 1028B to the inside of the tapered bore
in the body and permit to dry before assembly. RAD-1
material is used for nuclear applications.
2. Apply a light coating of oil or silicone to the interior of
the coining die or to the O.D. of the sleeve. Position the
sleeve in the coining die, part series #BY79542A, so that
the diagonal opposite sides of the sleeve port will lock
behind the metal lips in the body (Figure V B-2). The
sleeve is then pushed directly through the coining die
into the valve body until the sleeve drops below the top
counterbore of the valve body (Figure V B-1).
FIGURE V B-1 FIGURE V B-2
3. A special plug, part series
#BY79664A, containing
retractable or removable
blades is lowered into the
body with the blades re-
tracted or removed. The
blades are then installed or
extended and a counter
clockwise rotary motion is
applied to the plug engag-
ing the two remaining diag-
onal opposite sleeve port
openings and pulling them
until they fall behind the
body port lips. The plug is
then rotated back to its original position, and the blades
are then removed or retracted. The plug is then removed
from the body (Figure V B-2). In the 1" and 1
1 / 2 " sizes, a
bar may be substituted for the locking plug. See Figure
V B-2A for a description of this operation.
4. Apply a thin film of oil on
the sizing plug, part series
#BY79555A, and push it
into the sleeve until the siz-
ing plug flange bottoms
against the counterbore of
the valve body (Figure V B-3). Allow the sizing plug to
remain in this position for one minute.
5. Check that the inner diameter of the gasket pad of the
top cap has between a 1/6" x 45° to 3/32" x 45° chamfer.
If not, remachine the top cap to this dimension. See
Figure VB-4.
6. On a flat surface place the
top cap and adjuster sub-
assembly over the thrust
collar. Thread the fasteners
until snug.
7. The plug stem and
diaphragm guide should be
checked for nicks before
installing the diaphragm.
Nicks on these surfaces
could result in scratches
on the lip of the diaphragm.
The diaphragm (Part 6) is
assembled over the plug
stem with the aid of the
G4 diaphragm guide, part
series #BY86272A (Figure
V B-5).
SECTION V
B. VALVE ASSEMBLY – 1"-8" G4 MARATHON, G4R MARATHON
Push sleeve directly through coining
die until sleeve drops below top
counterbore of the valve body.
FIGURE V B-3
The sizing plug is pushed
into the sleeve until the
sizing plug flange bottoms
against the counterbore of
the valve body.
FIGURE V B-4
A special plug with retractable
or removable blades engages
the two remaining sleeve ports
and pulls them until they fall
behind the body port lips.
FIGURE V B-2A
Optional assembly operation
for 1" & 1
1 / 2 " G4 Valves
Care must be exercised to
ensure that the bar does not slip
and gouge or tear the sleeve.
FIGURE V B-5
If damaged the plug taper and
1" in length of stem must be
repolished to a surface finish
of 16 on the taper and stem.
DIRECTION OF
ROTARY MOTION
CHAMFER
OFFSET
SET ADJUSTER CAP SCREWS TO
MAKE ADJUSTER PARALLEL TO
TOP CAP
BOTTOM OF TOP CAP
AND THRUST COLLAR
DIAPHRAGM TO BE FLUSH