INSTALLATION & MAINTENANCE MANUAL

ROTOVALVE TABLE OF CONTENTS:

1 Introductory Information

1a Introduction to Rotovalves

1b Basic Function

1c Parts & Nomenclature

Figure 1

2 Safety

2a Safety (General Information)

2b Safety (During Handling and Installation)

2c Safety (During Operation and Maintenance)

3 Storage and Handling

Note

Handling

Storage (Up to One Year)

Storage(More than One Year)

4 Installation

5 Operation

Overview of Rotovalve Operation

General Description

Figure 5

Axial Movement of Plug Shaft for Seating and Unseating

Figure 5.1

Rotation of Plug for Opening and Closing

Figure 5.2

Detailed Operation of Rotovalve

Operation of Rotovalve/Cone Valve

6 Maintenance and Lubrication of Rotovalve

Once every Quarter (3 Months)

Semi-Annually (6 Months)

Lubricate

Recommended Lubricant

Once Yearly (12 Months)

Lubricate

Note

Figure 6

7 Troubleshooting Rotovalve Leaks Rotovalve Lifts and Begins to Rotate but Stalls Rotovalve Fails to Completely Open or Close

8 Repairing Information Rotovalve Plug and Body Plug and Body Seats Fasteners Bush and Lift Nut Coating (Paint)

9 Rotovalve Repairing, Disassembly and Reassembly Caution Disassembly and Reassembly Figure 9 Bushing Removal Valve Assembly Installing New Lift Nut

10 Warranty

1) INTRODUCTORY INFORMATION

1a) Introduction to Rotovalves.

The Rotovalve is a rugged and highly dependable liquid control valve, which can accurately modulate flows under extreme velocities, pressures and temperatures. Because of its design and construction the Rotovalve is a low maintenance valve, with many valves still in service 50 years after commissioning. These valves tolerate severe service conditions well. The lift and turn operation on the valve cone eliminates seat wear, which is so common in other types of valves. The valve achieves a full porting for a low head loss to the piping system. Of the construction features are: integrally cast trunions and mounting pads to assure proper alignment between the body, plug and mechanism; electrical fused Monel metal-to-metal seats handle sludge and grit; fully skirted plug with integrally cast trunions; moving parts totally enclosed in a lubricated, quickly removed, cast iron housing. This valves unique eating is via the lift and turn operation of the lift mechanism, resulting in no wear to seats and the seats being self-purging to assure tight closure. The valve can achieve a drip-tight shutoff against pressure or vacuum. Its easily controlled operating speed minimizes water hammer. Due to the valve design the Rotovalve achieves a two-stage pressure reduction, which eliminates vibration and cavitations.

1b) Basic Functions.

The valve functions as follows.

A) Closed = The Rotovalve seats drip tight with the machined Monel faces on both sides of the plug seating against the machined Monel surfaces of each side of the body.

B) Lift Actuation = The first movement of the actuator (manual, electric or hydraulic) moves the crosshead laterally, toward the rotator lever. This initial lateral movement of the crosshead moves the lifter lever, which turns the lift nut and raises the plug away from the body seat. At this point, the plug has not turned.

C) Opening = Once the crosshead contacts the rotator lever, further lateral movements of the crosshead then turns the plug.

D) Travel = Close-to-Open and Open-to-Close sequence can be adjusted for water hammer control. The two orifices of the valve (influent and effluent) drop the unbalanced pressure in two-stages, reducing the potential for cavitation and vibration.

E) Fully Open = Once the plug is fully rotated, continued movement of the crosshead turns the lift nut, reseating the plug against the seats.

1c) Parts & Nomenclature.

The following generic parts identification sketch is offered to help familiarize users with the features and components of this valve. Please note that information on the actuating device (manual, electric, or hydraulic) is contained on other instruction pages.

Figure 1

(2) SAFETY 2a) Safety (General Information):

1) All personnel should remember, SAFETY FIRST. 2) All equipment installation, operation and maintenance personnel should become familiar with this equipment and its basic modes of operation and equipment configurations. Untrained personnel should never attempt handling, installation, operation or maintenance of this equipment. 3) No personnel should attempt to handle or work with this equipment without having reviewed and understood the equipment drawings, and Operation and Maintenance literature. Actuators have specific safety precautions in their Operation and Maintenance literature. Be certain to read and understand all safety literature for these devices. 4) In addition to information provided by the equipment suppliers, use common sense, normal industrial safety practices, and compliance with local and national codes, when working with this equipment. 5) Never wear loose fitting clothing when handling, working with or servicing this equipment.

2b) Safety (During Handling and Installation):

1) During handling and installation, adhere strictly to chaining, hoisting and lifting safety standards. Never stand under or near equipment being transported by a hoist or crane. 2) Install Rotovalve equipment in accordance with the drawings provided for each complete assembly of equipment sold by VAG USA. 3) Do not allow site piping and plumbing to apply excessive force to the Rotovalve flanges. Excessive force can break flanges and/or valve body, or may cause distortion in the valve, thus causing the plug to not seat properly. 4) During installation, extreme care must be taken while moving loads via forklifts, hoists, and cranes, to avoid injury to equipment and/or personnel. 5) All chains, slings, cables, hoists, cranes, and forklifts, should be fully inspected and test rated for the lifting functions being performed. 6) Upon completing installation of this equipment, tightness and torque of all mounting bolts and set screws should be checked. Then testing of the installed equipment should begin.

2c) Safety (During Operation and Maintenance):

1) When valve is under pressure do not attempt to loosen the flange bolts or disassemble any portion of the Rotovalve body. 2) It is strongly recommended by VAG USA and required by OSHA that a

maintenance lock-out, tag-out, or other control system be established so that when personnel are in potentially dangerous areas or directly attempting to inspect or service a Rotovalve, the valve cannot be actuated. 3) Never place hands or tools in the path of a moving valve plug or actuating arms. 4) Do not alter this equipment or equipment configurations without first gaining approval of the proposed alteration by an Engineer or Field Service Technician at VAG USA. 5) Use only the manufacturer’s original replacement parts on this assembly. Contact VAG USAField Service Department for assistance with parts selections and price and delivery information. 6) In service Rotovalve should never be operated with the mechanism cover or lube fitting covers removed, crosshead and rotator arms are moving parts. If covers are removed for maintenance and/or lubrication the valve should be out of service, in the "no-load" condition with actuation power sources locked-out. 7) No amount of safety language and warnings in a notice can replace common sense, familiarity and knowledge of the equipment and equipment configurations, training and trained personnel, and the overall industrial motto "SAFETY FIRST". When in doubt, we recommend that you call VAG USA for assistance.

3) STORAGE AND HANDLING Note: This equipment should be thoroughly inspected upon receipt to ensure that no damage has occurred during shipment. If any damage is evident call VAG USA immediately so that freight claims can be made and corrective measures may be taken. Handling: Valves are usually shipped fully assembled (valve and operator). Skids are attached to the valve for unloading and handling with the Rotovalve in the same position as it will be installed. Great care should be taken when handling the Rotovalve assemblies. Rotovalve assemblies may be handled by fork-truck of the proper size and capacity for the Rotovalve. Care should be taken to evenly distribute the weight of the Rotovalve assembly on the forks. Rotovalve assemblies may be lifted by a properly sized crane, with lifting slings rated for the valve weight. When valves are lifted by a crane, lifting slings should be positioned to accomplish a three (3) point lift with the load evenly distributed on all three points. We recommend these attaching points to be as follows: one sling each at the inlet and outlet ports on the Rotovalve; one sling close to valve body on the operator flange. Do not lift the Rotovalve assembly by the operator. Lifting by the operator may cause damage to the operator and/or its coupling. Rotovalve assemblies should be handled as precision machinery. All normal industrial safety practices should be followed when handling this equipment. Storage (up to one year): VAG USA prefers that Rotovalve assemblies be stored in a clean and dry atmosphere, such as a warehouse. The operator provided on this valve may have specific storage instructions on other pages in this manual. We strongly recommend that the storage instructions for the operator be followed. If warehouse space is not available this equipment may be stored outside supported evenly on planks, timbers, pallets or skids raised to prevent intrusion of water. This equipment should be carefully covered with tarps, 4 mil opaque plastic, to protect from the weather and collection of foreign objects. Any special precautions given for the Rotovalve operator should be followed. Storage (more than one year): If this equipment will be in storage for more than one (1) year it will be necessary to call the VAG USA Field Service Department at (724)-776-1020. Our Field Service Technicians will discuss with you all of the available options and precautions for long term storage.

4) INSTALLATION: Rotovalves are a custom manufactured product which has been designed to meet the needs of a specific installation. Prior to attempting installation of the Rotovalve assembly, read the Operation and Maintenance manual and examine the drawings provided for the Rotovalve assembly. Pre-plan the installation of the Rotovalve assembly based on the particular needs and requirements of your site. Rotovalve assemblies should be carefully installed. The mounting flange of the Rotovalve should be thoroughly cleaned. Care should be taken to prevent damage to machined surfaces. Rigidly block the Rotovalve into place lining up the Rotovalve flange bolt holes with site piping flange bolt hole locations. A suitable gasket material (by others) should be installed between the Rotovalve flanges and field piping flanges. Flange nuts and bolts (by others), sized appropriately for the application, should be inserted into all flange holes and made finger tight. Care must be exercised when drawing flange bolts tight. At no time should an uneven strain be placed on the flanges. The adjoining pipeline should not exert a strain on the valve in any direction; such strain may break the valve flanges, crack the body and prevent the Rotovalve from seating properly. The Rotovalve flange nuts should be torqued as follows: picture the valve as a clock, tighten nuts in this order: 12:00, 5:00, 10:00, 8:00, 2:00, 9:00, 4:00, 7:00, 11:00, 3:00, 6:00, 1:00, etcetera, crisscrossing the flange until all nuts are tightened. This will provide for an even distribution of torque and the flanges will be pressed firmly together with no distortion to the mounting flanges or valve body. After initial tightening of all fasteners, torque all nuts in the order above to the torques values listed below. Torque applied to the bolt flange nuts and bolts for this should be determined by bolt hole and bolt and nut size as follows: Bolt Size/Torque Valve in Ft.Lbs.; 3/4"/150#; 7/8"/202#; 1"/300#; 1-1/8"/474#; 1-1/4"/659#; 1-1/2"/1057#; 1-3/4"/1884#; 2"/2721#. Valves larger than 10" in size are equipped with mounting bases. Anchor bolts (provided by others) should be sized appropriately for the application. After flanges are coupled and before the blocking is entirely removed, the base should be grouted with a non-shrink grout so that no strain is exerted on the valve body when the anchor bolts (by others) are tightened.

5) OPERATION OVERVIEW OF ROTOVALVE OPERATION: The Rotovalves unique method of operation reduces wear to seats and allows for quick and solid seating of the plug. The Rotovalve may be full open, full closed or at any intermediate position. The following is a brief overview of how a Rotovalve actuates: General Description: The Rotovalve is made of three major elements: a body, a conical plug operating within the body, and an operating mechanism. There is a full circular port through both the body and the plug. When aligned to the open position, this valve provides a continuous unobstructed passageway from flange to flange. This full line opening keeps head loss to a minimum and permits the use of pipe cleaning devices in the line. The top of the body is closed by a suitable head, through which the plug shaft extends to the operating mechanism. A housing mounted on the head encloses the operating mechanism which provides the sequence of mechanical interlocks to lift the plug, rotate, and realign the ports. The unique axial motion of the plug is developed by a rotating nut engaging on threads at the plug shaft. The nut is connected to a crosshead by a lever and link. The rotating lever is actuated by a roller attached to the same crosshead and arranged so that the crosshead operating in a straight line first effects a rotation of the lift nut. The plug is raised from its seats, then rotated 90 degrees realigning the waterways on the body and plug.

Figure 5

Axial Movement of Plug Shaft for Seating and Unseating: An "in-and-out" movement along the axial of plug shaft seats and unseats the plug. Movement is provided by rotations of the lift nut in a fixed plane by applying leverage to the lift lever through link and crosshead. The seating movement of the plug engages the plug seats with the body seats. The unseating movement lifts seats clear of body seats, allowing the plug to rotate freely on journal bearings. The lift-turn action is what sets the Rotovalve apart from other thru-ported valves.

Figure 5.1 Rotation of Plug for Opening and Closing: The plug is rotated on two journal bearings by applying leverage on plug shaft with rotator. The operator transmits motion through rod to crosshead and roller, to rotator which is firmly fixed to the plug shaft.

Figure 5.2 DETAILED OPERATION of ROTOVALVE: The Rotovalve is essentially a plug cock which in effect is first lifted from its seat and then rotated to the desired position. When in the open position, the opening through the circular plug orifice is, in general, equal to the opening through the adjoining pipeline, thereby providing an unobstructed fluid passageway. The passageway is closed by rotating the plug orifice 90 degrees, or perpendicular to the orifice in the valve body. The plug is forced into the main body so that the monel seat ring on the plug engage mating

seat rings on the body. The operating mechanism, and prime mover provide a vibration free valve plug when in the open or partially open position, the valve plug is positively locked by the rotator lever in all increments of the 90 degree movement. Prime mover power to operate the Rotovalve is transmitted to the crosshead which is guided by the rods that are held in firm position in the mechanism assembly, thereby effecting a straight line movement of the crosshead. It will be noticed from the sectional drawing that a roller attached to the crosshead operates the rotator lever which is provided with two flat contacting surfaces with a slot or dwell between them. The flat surfaces of the rotator lever are parallel to each other while the slot (dwell) is thrown at an angle off the radial line between them. The roller acting against the flat contacting surfaces holds the plug in a stationary position during the initial movement of the crosshead in the opening direction, permitting the link, which is also attached to the crosshead, to move. This movement of the link imparts a corresponding movement to the lifter lever to which it is also attached. By rotating the lifter lever and also the lift nut which are keyed together, and at the same time preventing a rotation of the plug shaft, the threads in the lift nut which engage the threads on the plug shaft act in effect as a jack screw causing an axial movement of the plug shaft and thereby unseating the plug. The lift nut is held from moving in an axial direction so that any rotation of the lift nut will cause the plug shaft to move axially either toward or away from the centerline of the valve. After the roller has moved the full distance on the contacting flat surface of the rotator lever, it engages the slot or dwell, and the rotation of the plug begins. The link being carried along and consequently rotating the lift nut in the same direction as the plug shaft, no further axial motion of the plug occurs, (due to the fact that the rate of rotation between the lift nut and plug shaft is somewhat different, a further slight axial movement lifts the plug further from the seat at some intermediate position). The slot or dwell of the rotator is at such an angle that with a uniform movement of the crosshead, the angular movement of the plug will be at a slower rate for at least the first half of its travel when operating from the closed to the open position. At the end of the rotation movement, there is a reversal of velocity effect between the lifter and the rotator lever, thereby imparting a reverse movement of the lifter lever to realign the plug and body waterways.

Figure 5.3 OPERATION OF ROTOVALVES/ CONE VALVE: The operation of Rotovalve (cone valves) is dependant upon the style (manual, electric, hydraulic, hydraulic-electric, air, etc) hat has been required or utilized for your application. Please see separate instructions for the provided operator for operation/actuation instructions for this Rotovalve.

6) MAINTENANCE AND LUBRICATION OF ROTOVALVE This equipment is designed for many years of trouble-free operation with very little maintenance required. The following maintenance procedures should be followed in order to sustain the Rotovalve's length of service: Once Every Quarter (3 months): Operate the Rotovalve through one full cycle open and closed. Listen to the valve actuation and observe for normal operation. Inspect the Rotovalve looking for abnormalities in the casting and flanges. Look for leaks and other signs of potential trouble. Outflow from the valve should be monitored to determine if the valve is seating tightly. Maintenance to the valve operator should be performed as scheduled on the actuator maintenance and lubrication information included in this manual. Semi-Annually (6 months): Perform the entire 3 month "quarterly" inspection and operation. Additionally, inspect Rotovalve anchorages and surrounding piping and flanges, as they attach to the Rotovalve body. Note any abnormalities and troubleshoot or repair as necessary. Lubricate and inspect the crosshead assembly. Lubricate: With the valve out of service in the full open or full closed position. disconnect, lock-out power and tag the lock-out per OSHA standards.

1) Lubricate the lift nut. At the base of the operating mechanism housing, locate the Alemite Fitting for lubrication of the lift nut. Lubricate to refusal at this fitting.

2) Remove the lube fitting covers on the crosshead and lubricate the two Alemite fittings. For Safety reasons never insert fingers into these openings, these Alemite fittings are located so that the nozzle of a grease gun can be held securely on the grease fittings while applying grease. Provide several full strokes of grease to each of the crosshead lube fittings. Replace the covers for the grease fittings. On the largest series of these valves there are heavy fabricated bolted covers for access to the crosshead lube fittings, remove the cover plates and lubricate the Alemite fitting on the crosshead. Inspect crosshead and replace the cover plate securely.

3) Some valves are manufactured with additional piped lubrication ports for lubrication of the lower bearing assembly, not recommended by VAG USA but required by some Engineers; please see your installation drawing or the actual equipment assembly for evidence of such lube piping and connections. If these additional lube ports and connections exist please lube to refusal.

Recommended Lubricant: Lubriplate 630 AA or any Lithium Based Extreme Pressure Grease, such as Mobil's Mobilith AW2, Shell Alvania, Valvoline Val-Lith, or equals. Lubrication Instruction Frequency Lubricant Lubricate crosshead mechanism

Once every six months Lubriplate 630 AA *

Lubricate upper and lower bearings at Alemite fittings – if so equipped (see valve drawing for guidance)

Once every twelve months Lubriplate 630 AA *

Alternative Lubricants to *: Mobil’s Mobolix Grease #EP-2

Shell, Alvania #2 EP

Maintenance to the valve operator should be performed as scheduled on the actuator maintenance and lubrication information sheets included in this manual. Once Every Year (12 months): Repeat the 3 month "quarterly" and 6 month "semi-annual" maintenance and lubrication procedures. Maintenance to the valve operator should be performed as scheduled on the maintenance and lubrication information sheets included in this manual. Lubricate: If your valve is equipped with lube ports for upper and lower bearings – lube these to refusal annually. Note: If inspections reveal that damage or repair work is required, see the "Repairing Information" provided in this manual for information on cleaning and repairing this equipment

Figure 6

7) TROUBLESHOOTING: The Rotovalve has been designed for many years of service if routine maintenance procedures are followed. Operation and maintenance personnel should become familiar with all aspects of this equipment and its operation. Care should be taken at time of valve installation, and application of electrical power and control wiring to the valve actuator. If the previous steps are followed there should be very little to actually troubleshoot. Rotovalve Leaks: Indicated by water flowing out of the controlled discharge after Rotovalve stops.

a) Actuator Failure. Check the Rotovalve actuator to determine if it is functioning properly. Has the actuator brought the valve through its full closing stroke? See actuator troubleshooting information included in this manual. b) Broken Lift Nut. This is sometimes indicated by the failure of the plug to reseat. Observe the shaft at the open/close indicator. Disassemble, inspect, repair and/or replace lift nut as necessary. c) Stress on Rotovalve Flanges. On new installations, leakage could be due to line stress on the Rotovalve flanges. With the valve line out of service loosen all flange bolts. Check for any misalignment. d) Worn or Severely Scored Seats. Back out the close stop adjusting screw, one turn at a time. If leakage is reduced, continue backing out one turn at a time until no further reduction is noted.

If no reduction in Rotovalve leakage is noted, the seats may be damaged beyond repair. Disassemble the Rotovalve and examine seats. If seats are severely scored, Rotovalve should be overhauled. Seat repairs in the field are not recommended. Rotovalve Lifts and Begins to Rotate but Stalls:

a) Actuator Failure. Check the Rotovalve actuator. The troubleshooting procedure for the actuator is contained in this manual. b) Severely Worn Plug, Body, and Head Bushings. This condition can be checked by operating the Rotovalve under no flow conditions. If the Rotovalve operates OK under no flow, bearing wear is usually the cause. Inspect the bearing, plug and body, and replace worn parts. c) Obstructions in the path of the valve plug. In order to sense or feel the obstruction on the plug, test this condition by manually actuating the Rotovalve. If an obstruction is apparent, fully open the Rotovalve and flush the line. If flushing does not clear the obstruction the Rotovalve will need to be taken out of service for disassembly of valve or piping lines to clear the obstruction.

Rotovalve Fails to Completely Open or Close:

a) Actuator Failure. Check the Rotovalve actuator. The troubleshooting procedure for the actuator is contained in this

manual. b) Mechanical Failure of Rotovalve Mechanism. Severely worn rotator and roller are indication of other mechanical problems. All mechanical parts should be fully examined; worn parts should be repaired and/or replaced. c) Foreign Material Between Seats. This usually occurs in sewage service. Foreign matter is caught between the plug and valve body. An angular rocking motion of the plug may dislodge the debris. If not, it may be necessary to disassemble the Rotovalve head, plug and crosshead mechanism.

After following the troubleshooting guides and attempting appropriate remedies, if you should still have operation problems with your Rotovalve, call Field Service Department for assistance. Have a brief description of the problem, the associated drawing numbers and VAG USA Shop Order number (SO#) available when you call. Tel.(724)-776-1020

8) REPAIRING INFORMATION: This equipment is designed for many years of service provided that it is properly installed and recommended maintenance procedures are followed. Under normal use and with proper care, repair of this equipment should not be necessary. If damage does occur, the following instructions should be followed. If questions remain, please contact the VAG USA, Field Service Department for assistance. Information sheets covering Rotovalve disassembly and reassembly, bushing removal, and lift nut installation follow this repairing information discussion. Rotovalve Plug and Body:

- Corrosion, and/or chips in the cast iron. = No repair procedure is recommended because it is necessary to assess the extent of the damage. Chips in these cast iron components can be measured and examined to determine the extent of damage. Small amounts of chipping will be of little to no concern. However chips that have occurred to the flanges and other machined areas may reduce the structural integrity of the Rotovalve. A VAG USA Field Service Technician should examine the extent of the damage and advise the best repair methods. - Cracks in the cast iron. = Any amount of cracking to cast iron components is of considerable concern. A full inspection of the Rotovalve and installation should be made to assess the extent of the damage. Such inspections should employ non-destructive testing methods, using dye penetrant. Inspector should be certified to ANSI SNT-TC1A level 2. Corrective measures should be taken to either replace or repair the damaged component. Cast iron welding is difficult to perform and of little benefit for Rotovalve repairs. A VAG USA Field Service Technician should examine the extent of the damage and advise the best repair.

Plug and Body Seats:

- If the monel seats allow leakage due to excessive scratches: = After troubleshooting and removing the cause of these scratches, buff the scratch out of the surface of the seats with a light emery board. If the scratches are too deep for removal by this process the valve must be removed and returned to VAG USA for repair of the seats.

Fasteners:

- Bent, broken, cracked or stripped. = All fasteners rendered inoperable because of damage or aging should be replaced.

Bushing and Lift Nut:

- If the bushings or lift nut are damaged for any reason, they will need to be replaced. = Check for damage to other components, and determine the reason for the bushing or lift nut damage. An extensive examination of the crosshead mechanism may be required. Damaged components should be replaced. Look up the VAG USA Shop Order number (SO#)

and associated drawing number for this installation. Call VAG USA Field Service Department (724)-776-1020 to order replacement parts.

Coating (Paint):

- Chips, and other small areas of damage to the coating. = Sand the specific spot, and repaint with the manufacturers recommended coating (see the material specification sheet and paint data included in this manual). - Large areas of coating failure. = Re-assess the site conditions to determine if the original coating is still correct for use at this location. Plug all points of entry, clean and sand blast the equipment. Re-paint Rotovalve with the recommended coating or a different coating if required by the conditions.

Information sheets covering Rotovalve disassembly and reassembly, bushing removal, and lift nut installation follow this repairing information discussion. If there should be other areas of concern consult the troubleshooting procedure, drawings, and other materials in the Operation and Maintenance manual. If questions remain, please contact VAG USA Field Service Department (724)-776-1020 and ask for assistance.

9) ROTOVALVE REPAIRING, DISASSEMBLY and REASSEMBLY Caution: Never attempt removal of bushings or other internal parts of the Rotovalve assembly, when the Rotovalve is "in service". Rotovalve should be out of service in the dry "no-head" condition. Electrical power to the Rotovalve actuator must be disconnected and trapped pressure in hydraulic lines (if any) must be relieved. A maintenance lock-out/tag-out procedure which conforms with OSHA regulations must be utilized. Disassembly and Reassembly:

1) Remove the position indication pointer. 2) Match mark mechanism housing and cover plate. 3) Remove cover plate. 4) Remove the rotator lever bolt. 5) Insert wedge, pry rotator lever loose and remove. 6) Count the number of threads showing on operator rod at stop screw end of mechanism and record that number. 7) Loosen jam nuts on both sides of crosshead and remove nut at stop screw end. At this point, it may be necessary to remove the end bearing to unscrew the jamb nut. If this is the case, match mark the end bearing and housing, then remove. Note the end bearing is pinned and bolted to the mechanism housing. 8) Disconnect any controls mounted to Rotovalve head and remove. 9) Match mark operator output shaft and adapter plate. 10) Remove the operator. Remove the rotator lever. Note: After removing the retainer bolt, on the rotating lever, use a wedge to spread the rotator lever for easy removal. 11) Remove the crosshead, lift the link, and the lift lever out as an assembly. To do so, remove the bolt securing the lift lever to the lift nut. Use a wedge to spread the lever. The crosshead, lift lever and lift link can now be pulled as a unit. 12) Match mark the thrust collar with housing and remove. 13) Match mark lift nut and thread on mechanism shaft so that at reassembly, nut will be started on proper thread. 14) Remove lift nut. 15) Tape mechanism shaft threads so that the oil seal in the housing will not hang up when the housing is removed. 16) Match mark housing and head. Remove housing. 17) Match mark mechanism shaft and coupling. Remove bottom pin. Remove shaft and coupling as a unit. 18) Match mark head and body. Remove head bolts. 19) Loosen packing gland. Packing is more easily removed after the head has been removed. 20) Remove head and head "O"-ring. 21) Remove plug. Care should be taken to avoid damaging seats upon removal. If the valve has been removed from line; match mark waterway.

Figure 9

Bushing Removal: 1) Plug bushings should be heated to aid in removal. Use a chisel to cut bushing to be replaced. 2) To remove body bushings, a groove should be cut into the edge of the bushing with a chisel or small grinder. Care must be taken to avoid damaging the trunion areas when cutting bushings. Bushings should then be pushed away from the bore at the point the cut was made. Using a chisel or grinder, continue cutting the bushing and pushing it away from the bore as cut is made.

Valve Assembly: Reassembly of the Rotovalve is the inverse of the above procedures, with the following notes:

1) Lower the plug slowly to avoid damage to plug and body seats. 2) To align bushing rotate plug while lowering. 3) After head and "O"-ring have been placed on body, start head bolts but do not tighten. At this point, lift plug and turn to check for free movement. If plug lifts and turns freely, reseat plug in closed position. Align match marks and tighten head bolts. 4) When installing the lift nut, make sure match marks on the lift nut align with marks on mechanism shaft thread. Note: For installation of a new lift nut see the procedure provided in this section of the manual. 5) Lift lever should be flush with top of the lift nut. 6) Guide rods should have 1/16" to 1/8" free play. 7) Proper lift can be checked by using a .009 feeler gage insert between plug seat and body seat.

Installing New Lift Nut:

1) Install new lift nut and the parts removed to access the lift nut in the reverse order. Follow the disassembly and reassembly instructions. Do not over-tighten lift lever on the lift nut. 2) Use the operator to position the crosshead. 3) Snug the lift lever. Do not over-tighten. Put a scribed line across the top of the lift nut and lift lever. 4) Use the operator to close the valve fully. Valve is fully closed when the crosshead is against the stop screw. 5) If the scribed line on the lift nut still matches the one on the lift lever, loosen the lever, return the crosshead to position. Put a new scribed line across the lift nut and the lift lever, as before. Tighten the lift lever and close the valve. Repeat this procedure until the scribed line indicates the lift lever is slipping on the lift nut. This slipping indicates the valve is seated. 6) Loosen the lift lever and position the crosshead so there is a gap of 1/2" to 5/8" between the crosshead and the stop screw. Tighten the lift lever. 7) Remove the lift lever and guide rods. 8) Drill a hole in the lift nut and lift lever for the dowel pin. Install dowel pin. 9) Install rotator lever and guide rods. 10) Complete reassembly of operating mechanism and operator.

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WARRANTY For a period of one year from the date of shipment, and provided payments for the Products have been made by Buyer to

Seller, Seller warrants to Buyer that its Products: (i) substantially conform to Seller’s published specifications and (ii) are

free from defects in material or workmanship. Specific products may have a warranty period greater than one year. Any

Services provided by Seller are warranted to be performed in a good and workmanlike manner. Should a warranted

Product or any Services fail to conform to these warranties, Buyer must promptly notify Seller in writing. Seller will, at

its discretion and at no charge to the Buyer: (i) repair the Product or Services; (ii) replace the Product or any Services; or

(iii) offer a full refund of that portion of the purchase price allocable to the non-conforming Product or Services. Warranty

repair or replacement by Seller shall not extend or renew the applicable warranty period. Buyer shall obtain Seller's

agreement on the specifications of any tests it plans to conduct to determine whether a non-conformance exists. Buyer

shall bear the costs of access for Seller's remedial warranty efforts (including removal and replacement of systems,

structures or other parts of Buyer's facility), de-installation, decontamination and re-installation. THE FOREGOING

WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE. This warranty allocates the risks of Product failure between Seller and Buyer. This allocation is recognized

by both parties and is reflected in the price of the goods. Buyer acknowledges that it has read VAG USA, LLC’s Terms

and Conditions of Sale, understands it, and agrees to and is bound by its terms.

WHAT IS NOT COVERED BY WARRANTY

No representative of Seller has authority to waive, alter, vary or add to the terms hereof without prior written approval of

an officer of Seller. Seller’s warranty does not apply to: (i) dynamic vibrations imposed by the drive system in which

such Products are installed unless the nature of such vibrations has been defined and accepted in writing by Company as

a condition of operation; (ii) improper or unauthorized repair, installation or maintenance of the Products by a party

other than Seller; (iii) use for purposes other than those for which designed, or other abuse, negligence, misuse, or

normal wear and tear; (iv) unauthorized attachments, modifications or disassembly; (v) damage during shipping; or (vi)

Products purchased from unauthorized distributors, resellers or internet sites. Buyer’s care in selection, adequate testing

at time of installation and proper installation, operation and maintenance of all Products is required for adequate

performance.

LIMITATIONS OF LIABILITY

NOTWITHSTANDING ANY PROVISION OF THIS CONTRACT OR THE LAW, IT IS EXPRESSLY AGREED

THAT SELLER’S TOTAL LIABILITY FOR ANY DAMAGES, COSTS OR EXPENSES ARISING OUT OF OR

RELATED TO THIS CONTRACT OR ITS PRODUCTS OR SERVICES, WHETHER BASED IN CONTRACT,

WARRANTY, INDEMNITY, TORT/EXTRA-CONTRACTUAL LIABILITY (INCLUDING NEGLIGENCE),

STRICT LIABILITY OR OTHERWISE IS LIMITED TO THE REPAIR OR REPLACEMENT OF THE PRODUCT

OR SERVICES OR, AT SELLER’S OPTION, A RETURN OF AN AMOUNT THAT SHALL NOT EXCEED THE

PURCHASE PRICE. UNDER NO CIRCUMSTANCES WILL SELLER, IT’S OFFICERS, DIRECTORS,

EMPLOYEES OR ASSIGNS BE LIABLE FOR ANY OTHER REMEDY, LOSS, COST, DAMAGE OR EXPENSE

WHETHER DIRECT OR INDIRECT. IN NO EVENT WHATSOEVER SHALL SELLER BE LIABLE FOR ANY

CONSEQUENTIAL, LIQUIDATE, EXEMPLARY OR PUNITIVE DAMAGES, INCLUDING BUT NOT LIMITED

TO, LOSS OF USE, INCOME, PROFIT, OR PRODUCTION; INCREASED COST OF OPERATION, SPOILAGE OR

DAMAGE TO MATERIAL, OR CHANGE OUT COSTS. BUYER SHALL INDEMNIFY, DEFEND AND HOLD

SELLER HARMLESS FROM ANY LOSS, COST, EXPENSE, DAMAGE, OR CAUSE OF ACTION TO OR BY A

THIRD PARTY THAT EXCEEDS THESE LIMITATIONS OF LIABILITY.