OPERATION AND MAINTENANCE INSTRUCTIONS

202F/204F SERIES TWO-PIECE BALL VALVE

Sizes ¼”– 3”

Thank you for purchasing Inline Industries’ 202F/204F Series 2-Piece Ball Valve. This product has been constructed for outstanding performance over a wide range of service applications. The 202F/204F can be used as a manually operated valve with a standard lockout device.

Available with threaded end connections, the 202F/204F is an outstanding choice for your general purpose and automated fluid processing needs.

Installation and Operation

Always install your valve according to accepted industry standards and practices and operate only within stated pressure, temperature and fluid media limits. Do not open or disassemble valve unless you intend to replace resilient seat and gasket materials. Repair kits are available from your local Inline representative or call 1-800-568-8998.

Your 202F/204F valve is available lever operated with our standard lockout device Product specification sheets and technical drawings are available for dimensional information required for proper installation and automation.

Maintenance

Resilient seated valve products may wear over time resulting in loosening at component boundaries. If leakage is detected, tighten according to the steps and torque values outlined below. If tightening does not correct the problem, it is time to replace your seats and seals.

Repair

Remove and Clean Valve

A. If valve is in line, make sure system is purged and line, ball and cavity pressure are released before unbolting from piping system.

B. Remove all add-on components such as actuators, stem extensions, etc. and set aside.

C. Disassemble valve by loosening end cap counterclockwise. Remove old seats and seals and discard them. Clean and dry metal components in preparation for reassembly.

Install Repair Kit and Reassemble Valve

Arrange cleaned valve parts on workbench.

A. Stem Assembly

1. Place Thrust Washer on Stem sliding over threaded end and seating on shoulder at base.

2. Insert Stem into Body cavity through side, threaded end first, and glide through the hole in the top of the Body until seated.

3. While holding Stem in place, slide Stem Packing set over threaded end. Stem Packing should be stacked with mating concave/convex sides facing each other. Slide Stem Packing set over Stem, concave piece first, until seated.

4. Place Stem Packing Bushing over threaded end of the Stem and lower over Stem Packing set.

5. Position Spring Washers with concave sides facing each other and lower set over Stem bringing them to rest upon Stem Packing Bushing.

6. Thread Stem Nut down Stem and hand tighten until Stem and Packing Assembly are properly seated aligned and fixed in position. Tighten Stem Nut to the minimum torque specified in Table 1 and rotate slightly more until Stem Nut flats are perpendicular to Stem flats. This will allow you to slide the Lock Washer down Stem and into position over Stem Nut. (Please note: torque should not exceed maximum indicated in Table 1.) Thread second Stem Nut down over Stem until resting on Lock Washer to keep Stem Assembly locked in place for further valve assembly and adjustments.

B. Ball/End Cap

1. Position the valve body with the female threaded end resting on the workbench. The open body cavity should be facing toward the ceiling. Place one (1) new seat into the pocket machined into the bottom of the body cavity with the curved side facing up.

2. Make sure seat is properly positioned in body cavity. Turn handle to the normally closed position to orient the axis of the key at the base of the stem vertically so as to facilitate ball entry. Carefully lower ball into the body cavity gliding ball key way over stem key until cradled on seat. Rotate ball 90º to prevent ball from moving.

3. Select the body seal provided. Gently insert the body seal into the step machined into the open end of the body.

4. Lay valve body down on its side on the workbench.

5. Position the end cap with female threaded end resting on the workbench. Place one (1) new seat in end cap.

6. Carefully insert the end cap, male threaded end first, into the body cavity and rotate clockwise until you feel resistance. Make sure that both seats are securely positioned into their respective machined pockets before continuing. Continue hand tightening until end cap has secured ball into position.

7. Ball should now be loosely secure. Turn the valve upright and inspect to see that the stem is straight and ball orifice is aligned with the end cap bore hole.

8. Tighten end cap with a torque wrench to the force values specified in Table 2.

C. Final Assembly and Test

1. Your 202F/204F ball valve is now ready for final assembly, adjustment, and testing. Remove top stem nut. Next, slide handle over stem. Hand-tighten stem nut until handle is fixed in place. Secure with wrench.

2. Submit valve to qualified valve test facility for pressure test.

Your repaired 202F/204F ball valve is now ready for installation and service.

Inline Industries makes a number of other fluid processing valves, which complement this offering. Thank you for purchasing an Inline product.

Table 1. 202F/204F Suggested torque for stem packing gland nut.

	Type and size of ball valve	Torque
Gland Nut Size	202F/204F	(in.-lbs.)
M12	¼”—¾”	70 – 80
M14	1” – 1 ¼”	85 – 95
M18	1 ½” – 2”	105 – 115
M22	2 ½” – 3”	145 – 160
M28	4”	170 – 185

Table 2. 202F/204F Suggested tightening torque for ball valve end cap.