Apollo Conbraco 6PLF Installation Manual

Installation, Operation and Maintenance Instructions

Valve
Size

6PLF

Lead Free

2”

6PLF-208-01

2-1/2”

6PLF-209-01

3”

6PLF-200-01

4”

6PLF-20A-01

6”

6PLF-20C-01

8”

6PLF-20E-01

10”

6PLF-20G-01

Valve
Size

Actuation

Kit

Description

2”

78253001

KIT,MTG,6PLF208 TO A0150

2-1/2”

78253101

KIT,MTG,6PLF209 TO A0150

3”

78253201

KIT,MTG,6PLF200 TO A0200

4”

78253301

KIT,MTG,6PLF20A TO A0350/0600

6”

78253401

KIT,MTG,6PLF20C TO A0950

8”&10”

78253501

KIT,MTG,6PLF20E/20G TO A1600/A2500

Valve
Size

Gland Bolt

Size

Torque

(max.)

2”

1/2”-13UNC X 38mm

20 ft-lbs

2-1/2”

1/2”-13UNC X 38mm

20 ft-lbs

3”

1/2”-13UNC X 38mm

20 ft-lbs

4”

1/2”-13UNC X 38mm

20 ft-lbs

6”

1/2”-13UNC X 50.8mm

45 ft-lbs

8”

1/2”-13UNC X 50.8mm

45 ft-lbs

10”

1/2”-13UNC X 50.8mm

93 ft-lbs

6PLF Series

Lead Free Cast Iron Ball Valves

Introduction

This manual presents guidelines for the Installation, Operation
and Maintenance of Apollo International’s Lead Free Cast
Iron Ball Valve, the 6PLF Series. Review the entire manual
before beginning any work.

Installation

Proper valve selection is the first step in any successful
installation. For application guidance or for more detailed
assistance, contact your distributor or the factory.

Pre-Installation Inspection

A leading cause of premature valve failure is poor
house-keeping. Inspect the piping system prior to valve
installation, whenever possible, to insure that it has been
properly flushed and cleared of construction and fabrication
debris. The seating surfaces in soft seated valves are
particularly susceptible to weld slag and sand blasting grit.
Pipe scale, metal chips and other foreign materials should be
removed.

Prior to installation, remove the valve from its packaging and
remove any end covers. Examine the flow bore for debris. All
of Apollo International’s ball valves are shipped in the open
position to prevent damage to the ball surface. Any foreign
matter must be removed. Do not install a damaged valve.

Flanged End Valve Installation

After determining that the valve is in good condition, attention
should be given to the flange face. Dents and heavy
scratches should be repaired. Do not install damaged valves.

Apollo International’s Cast Iron Ball valves may be installed in
any position using standard pipe fitting practices. Special
considerations are required when bolting cast iron valves to
steel flanges. When Class 125 CI valves are to be bolted to
Class 150 steel flanges, the steel flanges shall be flat faced.
Due to the brittle nature of cast iron, consideration should also
be given to proper piping alignment.

for

Actuator Installation

To convert from a handle assembly to an actuator assembly,
remove the handle assembly, handle follower plate, gland
bolts, square gland plate, and packing follower.
Assemble the oval gland plate and the gland bolts. Tighten

the gland bolts according to the table below in “Valve

Adjustments.”

Assemble the bracket, coupling and the actuator to the valve.

Operation

The 6PLF series features a quarter turn operation; full open to
full closed. Standard operation is clockwise to close. Valves

2” through 6” are furnished standard with a lever operator.
The 8” and 10” valves have gear operators and handwheels

as standard.

Maintenance

Due to its simplicity, the only preventive maintenance is to
periodically inspect the valve for leaks and ease of operation.

Do not disassemble or remove any part from a valve
under pressure. Before removing a valve from the line, place

it in the half-open position to remove any line pressure or
pressure trapped in the body cavity.

Valve Adjustments

The stem packing was adjusted at the factory to provide a
leak-tight seal when the valve was new but, compaction can
occur within these seals that makes readjustment necessary.
Stem leakage should be stopped as soon as it is detected.
Adjust the packing gland bolts per the following table:

Do not over tighten. Over-tightening will result in excessive
operating torque. If stem leakage continues, or operating
torque becomes excessive, de-pressurize the valve and
replace the stem seals. Obtain repair kits from the factory.

1 I981900, Rev A

ECN# M14751

Valves with high operating torque not resulting from stem seal

Valve
Size

Soft Goods

Repair Kit

Description

2”

6PLF-028-01

KIT,SERVICE,IBVLF-125-2”

2-1/2”

6PLF-029-01

KIT,SERVICE,IBVLF-125-2-1/2”

3”

6PLF-020-01

KIT,SERVICE,IBVLF-125-3”

4”

6PLF-02A-01

KIT,SERVICE,IBVLF-125-4”

6”

6PLF-02C-01

KIT,SERVICE,IBVLF-125-6”

8”

6PLF-02E-01

KIT,SERVICE,IBVLF-125-8”

10”

6PLF-02G-01

KIT,SERVICE,IBVLF-125-10”

Valve
Size

Body Bolt
Size

Torque
(max.)

2”

M14 X 50mm

45 ft-lbs

2-1/2”

M14 X 53mm

45 ft-lbs

3”

M14 X 53mm

45 ft-lbs

4”

M16 X 60mm

45 ft-lbs

6”

M20 X 70mm

57 ft-lbs

8”

M20 X 75mm

93 ft-lbs

10”

M20 X 75mm

93 ft-lbs

over tightening or valves which have leakage past the seats
may have damaged seats or ball surfaces. These valves
should be de-pressurized, removed from the piping system,
disassembled and inspected for damage.

Valve Overhaul

The first step is to contact your distributor to acquire an
appropriate rebuild kit. These kits contain a complete set of
seats, seals and gaskets.

Disassembly Process

1. Assure appropriately sized wrenches and lifting devices
are available.

2. Place the valve in the half-open position, assuring no
pressure is trapped in the valve body.

3. Handle: Remove handle assembly, indicator follower,
locking plate, gland fasteners, gland plate and gland ring.

4. Gear Operator: Remove gear operator, bracket, packing
gland fasteners, and gland plate.

5. Remove the body bolts and remove the tail piece from
the valve body.

6. Using an appropriate lifting device, remove the ball from
the body cavity.

7. Remove the stem from the valve body. Due to presence
of corrosion products it may be necessary to drive the
stem from the valve body using a soft face hammer,
being careful not to damage the stem.

Inspection

Note: If replacement of the body or ball is required, we
recommend replacement of the entire valve.

1. Thoroughly clean all the components in preparation for
inspection.

2. Examine the sealing surfaces within the body. If these
surfaces are pitted or deeply scratched the valve must be
replaced. A scratch is anything you can feel with your
fingernail. Machining marks may be present and will not
interfere with sealing. Scratches that can be seen but not
felt may be polished out using #120 grit emery cloth or
finer.

3. Examine the stuffing box. Polish these surfaces with
#120 (or finer) grit emery cloth and inspect for pits and
scratches. Deep scratches running down the side of the
stuffing box will necessitate the replacement of the valve.

4. Examine the stem. Machine marks may be present
extending around the part. These will not interfere with
effective sealing. If longitudinal scratches or pitting is
present, the stem must be replaced.

5. If the ball has pits or scratches as described above, it
should be replaced.

6. Inspect the spare parts provided to assure they are
correct, in good condition and have not suffered damage
in storage or shipment.

Re-assembly

1. Use a lubricant which is recommended for the intended
service. Only small amounts of assembly lubricants are
necessary.

2. Lubricate/grease the new seats and install them in the
body and tail piece.

3. Lubricate/grease the stem. Install the thrust washer on
the stem and install the stem in the body.

4. Lubricate/grease the new stem packing rings and place
them one at a time over the stem and push them to the
bottom of the stuffing box.

5. Lubricate/grease the gland ring/gland plate and install
with the original gland bolts provided they are in good
condition. Tighten only finger tight at this time. Rotate the
stem to the closed position.

6. Place the body with the cavity facing upward. Lower the
ball into the body cavity making sure the stem slot in the
ball aligns with the tang on the stem. The ball should
come to rest on the body seat.

7. Set the new body gasket in place.

8. Set the tail piece onto the body. On larger tail pieces use
appropriate lifting equipment to set the tailpiece. Lift the
tail piece by opposite pipeline flange bolt holes and lower
it onto the body.

9. Align the pipeline flange bolt patterns (two-hole).

10. Install the body fasteners hand tight. Torque to the value
indicated in the table below in three equal steps using a
criss-cross pattern.

11. Torque the packing gland fasteners to the level indicated
in the section >Valve Adjustments<.

12. Install the operating mechanism, lever or gear, in its
original orientation. Cycle the valve three to five times to
assure smooth operation.

13. Complete the re-assembly with a check of the body bolt
torque by going around the bolt pattern clockwise at the
specified level. Check the packing gland fasteners torque
again at this time.

14. The valve is now ready for testing and use.

Final Adjustments
Occasionally after testing or initial start-up, a minor stem or
packing leak may occur. Adjust the packing plate bolts in
accordance with the section entitled "Valve Adjustments".

2 I981900, Rev A

ECN# M14751