Cashco QCT User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

RANGER QCT

ROTARY CONTROL VALVE BODY ASSEMBLY

FLANGED OR FLANGELESS DESIGN

I. DESCRIPTION AND SCOPE

This manual covers the body assembly of the Cashco
Ranger QCT. Available sizes include 1", 1-1/2", 2",
3", 4", 6" and 8" (DN25, 40, 50, 80, 100, 150, 200).
Flangeless DI bodies fi t 150 and 300 lb. RF fl anges.
Flangeless CS and SST bodies, all sizes, fi t 150, 300
and 600 lb. RF fl anges. Integral fl anged CS and SST
bodies, sizes 1" through 3", mate with 150, 300 and
600 lb. RF fl anges. Integral fl anged CS and SST bod-
ies, sizes 4", 6" and 8", mate with 150 and 300 lb. RF
Flanges. All sizes of fl angeless construction may be
installed between PN40 fl ang es. Quick Change Trim
(QCT) is furnished as a stan dard feature and allows
use of several seal re tain ers and inserts to vary orifi ce
size, help control cav i ta tion and reduce noise. All trims
use 90° plug rotation. Dis as sem bly, in spec tion and
reassembly of the trim can be accomplished easily
without disturbing the packing, linkage or po si tion er
calibration. Trim parts are self-centering.

IOM-Ranger

12-13

SECTION I

Either of Cashco's pneumatically actuated actuators,
Model 48 and Model 148, can be mounted to the
Ranger QCT body.

II. REFERENCES

Refer to Technical Bulletin Ranger-TB for complete
tech ni cal specifi cations coupled with either Cashco
Actuator Model 48 or 148.

www.cashco.com/techbulletins/ranger.pdf

Refer to following Installation, Operation & Main­ te nance Manuals (IOM’s) for either actuator and/or
devices that maybe mounted to a Model Range body:

Actuators: www.cashco.com/IOM/48.pdf
www.cashco.com/IOM/148.pdf
Positioners:
P/P: www.cashco.com/techbulletins/73.pdf
P/P: www.cashco.com/techbulletins/9540r.pdf
I/P: www.cashco.com/techbulletins/srd991.pdf
I/P: www.cashco.com/iom/PS2iom.pdf

SECTION II

ABBREVIATIONS

ATC-FO – Air-to-Close, Fail Open
ATO-FC – Air-to-Open, Fail Close
CCW – Counter-Clockwise Rotation
CS – Cast Carbon Steel
CW – Clockwise Rotation
CWP – Cold Working Pressure
DIR – Direct Acting
DI – Ductile Iron
IAS – Instrument Air Supply
IOM – Installation, Operation and Maintenance
Manual
LOAD – Positioner Output Air Pressure
REV – Reverse Acting
RF – Raised Face
SIG – Output Signal from Instrument
SST – Cast or Wrought 316 Stainless Steel
V – Vent

III. INSTALLATION

SECTION III

A. Orientation:

1. Preferred orientation when valve is installed
in either a horizontal or vertical pipeline is
with the valve stem horizontal. Valves may
be installed with the stem any where between
horizontal or vertical for all sizes.

2. Ranger QCT valve with actuator is not rec­ om mend ed for installation with the actuator
ori ent ed down wards.

3. In no case is additional weight to be applied
to the actuator subassembly when installed
in any orientation.

WARNING

The valve/actuator unit should not be used as a “step” to
support personnel. Failure to comply may cause leak age
at the fl ange/valve body joint, especially for fl angeless
body design.

2. If the pipe reducers, elbows, noise at ten u a tion
de vic es, etc., are located before and/or after
the valve body, keep these pieces as close
as practical to the valve body.

NOTES: 1. For fl angeless design, allow suf-

fi cient clear ance up stream from valve body for
line bolt in ser tion and removal. See Figure 2
and Ta ble 1.

2. Undue piping stress/strain or bending­torques may not be transmitted through the
control valve body. One pipe (inlet or outlet)
should be anchored rigidly for piping that is
“hot” or “cold’” with respect to ambient tem­ per a ture; the remaining pipe (inlet or outlet)
should be supported and guided to ensure
uni di rec tion al expansion/con trac tion. Prop er ly
align prior to installing valve with required
fl ange bolting.

3. Clean the piping of all foreign debris, including
chips, weld scale, weld splatter, oil, grease,
sand or dirt, prior to installing the control valve.
THIS IS AN AB SO LUTE RE QUIRE MENT!

B. Piping System:

1. It is recommended that the control valve unit
be installed with a double-block and bypass
as indicated in Figure 1. This arrangement is
necessary when main te nance is to be done
on the valve body. Valve must be removed
from the pipeline to gain access to unit’s
internal trim parts.

BLOCK

_

MANUAL BYPASS

SIG

LOA

AIRSET

I/P

PO SIT

V

4. Field hydrostatic testing the completed pip­ing system, including the Ranger QCT valve,
to the max allowable CWP indicated on the
valve’s name plate is acceptable. If hydro test
pres sure is to exceed this limit, the Rang er
QCT must be removed before such test ing.
Be fore pres sur iza tion, the valve plug must be
rotated out of the seat if of reverse, ATO-FC
action.

IAS

BLOCK

CONTROL

VALVE

DRAINDRAIN

FIGURE 1: Typical Control Valve Station

FIGURE 2: Line Bolting Clearance

IOM-Ranger2

Body Size

1" (DN25)

1-1/2" (DN40)

2" (DN50)

3" (DN80)

4" (DN100)

6" (DN150)

8" (DN200)

TABLE 1 – LINE BOLTING REMOVAL CLEARANCE

Reducer

Size

None

1-1/2"x1"

2"x1"

2-1/2"x1" 7.38 (187)

None

2"x1-1/2"

2-1/2"x1-1/2"

3"x1-1/2"

4"-1-1/2" 7.44 (198) 8.88 (226)

None

2-1/2"x2"

3"x2"

4"x2" 9.00 (229)

None

4"x3"

6"x3" 10.25 (260) 12.19 (310)

None

6"x4"

8"x4"

10"x4"

None

8"x6"

10"x6"

12x6"

14"x6"

None

10"x8"

12"x8"

14"x8"

16"x8"

150# Flgs. 300# Flgs. 600# Flgs.

L1 L2 L1 L2 L1 L2

Min

8.38

(213)

8.44

(214)

10.06
(256)

11.50
(292)

12.50
(318)

14.81
(376)

15.50
(394)

Min

Min

Min

Min Min Min

Min Min Min

Min Min Min

Min

Min

Min

Min

Min Min Min

Min

Min Min Min

11.0 (279) 12.00 (305)

Min

Min Min Min

Min Min Min

12.75 (324) 14.00 (356) 16.56 (421)

Min

Min Min Min

Min Min Min

15.50 (394)

8.75

(222)

9.88

(251)

10.13
(257)

13.44
(341)

13.56
(344)

16.25
(413)

18.75
(476)

Min

Min

Min

Min

Min

Min

Min

16.68
(424)

8.94

(227)

10.12
(257)

10.50
(267)

13.88
(353)

16.00
(406)

18.63
(473)

20.38
(518)

Min

Min

9.12 (232)

Min

Min

12.63 (321)

Min

14.50 (368)

Min

Min

17.93 (455)

C. Plug Position for Installation:

CAUTION

DO NOT IN STALL ANY RANGER QCT VALVE WITH
THE PLUG IN THE OPEN POSITION. The cage and
seals may shift during installation. The resulting mis align­ ment of plug and seals will negate the Class IV or Class
VI seat leakage capabilities.

NOTE: All ATC-FO valves are shipped from the
factory in the closed position to ensure align ment
of body trim internals. After installing valve body
in piping system, rotate valve plug to full open
po si tion.

1. All indicated Item Numbers that are with re­ spect to IOM-48 or IOM148 will be in pa ren­ the sis and underscored; i.e. (20); the same is
true for the positioner parts. All Item Numbers
that are with respect to this IOM-Ranger are
not underscored; i.e. (6).

IOM-Ranger

2. For ATC-FO Direct Action Valves with Hand­wheel Assembly:
a. After installation in piping, loosen locking

le ver (59) and turn handwheel (58) CCW
to fully open the plug (6).

b. Check travel indicator (16) to confi rm

valves full open plug po si tion.

c. Tighten locking lever (59).

3. For ATC-FO Direct Action Valves without
Handwheel Assembly:

NOTE: For shipping and installation purposes

these valves use a mechanical device to tem­porarily hold the plug in the closed po si tion. A
slotted “C” washer is positioned on the push
rod (10) between the lower case (2) and the
upper jam nut (43). See Figure 23.

a. After installation of valve in piping, con-

nect a temporary air supply with an in-line
adjustable airset reg u la tor with gauge to
the actuator top works.

3

b. Pressurize the actuator to a level 2-3 psig

(0.1–0.2 Barg) above the upper pressure
lev el of the bench setting as stated on the
name plate (21); i.e. 5–15 psig (.34–1.03
Barg) range, set pressure at 17–18 psig
(1.17–1.24 Barg).

c. Remove machine screws (36) and cov er

plate (20).

d. Locate “C” washer and remove. Re tight en

upper jam nut (43) to lower jam nut (43).
Re place cov er plate (20) and ma chine
screws (36).

e. De pres sur ize the actuator and check

trav el indicator (16) for full plug travel.
Disconnect temporary air supply.

NOTE: Save slotted “C” washer for reuse
when reinstalling the valve back into the
pip ing.

WARNING

Do not adjust temporary air supply pressure after cover
plate (20) has been removed. Valve contains parts which
could move during maintenance exposing hand and/or
fi ngers to a hazardous condition.

D. Body Installation:

TABLE 2

Recommended Line Bolting Dimensions

Valve Size

1"

1-1/2"

2"

3"

4"

6"

8"

Line Flange
ANSI Class

150 1/2"-13 4 7.75"

300-600 5/8"-11 4 8.00"

150 1/2"-13 4 7.75"

300-600 3/4"-10 4 9.00"

150 5/8"-11 4 9.25"

300-600 5/8"-11 8 9.25"

150 5/8"-11 4 10.50"

300-600 3/4"-10 8 12.25"

150 5/8"-11 8 11.50"

300 3/4"-10 8 12.25"

600 7/8"-9 8 14.25"

150 3/4"-10 8 13.75"

300

600

150 3/4"-10 8 15.50"

300

Dia.-Thd. UNC Qty. Length

Tie Rod Studs

3/4"-10 10 14.75"

3/4"-10 4 5.50

1"-8 10 16.50"

1"-8 4 6.75"

7/8"-9 10 16.50"

7/8"-9 4 6.25"

3. Line Bolting Material must comply with ANSI B16.34
and be compatible with the in tend ed service.

The Ranger QCT body can be installed be tween
ANSI Class 150, 300 or 600 lb. RF or FF fl anges
or their ISO equivalent of PN20, 50 or 100. Socket
weld, weld neck or slip on companion fl anges
can be used. Face-to-face di men sions are per
ISA 75.08.02.

1. Install valve so the fl ow direction matches the
arrow on the valve body.

2. For fl angeless design alignment, special
boss es cast on the valve body contact the
line bolting and help center the valve in the
pipe line. See Table 2 for Line Bolting Di men­ sions.

CAUTION

DO NOT USE THE RANGER BODY ASSEMBLY AND
LINE BOLTING TO PULL FLANGE PIPE ENDS INTO
ALIGNMENT. Seal retainer may shift, dam ag ing the
seal retainer gasket allowing leakage between body
and seal retainer. Movement of seal retainer may
compromise the valve's ability to meet stated shut-off
leakage rates. Could also allow leak age between body
and fl ange pipe ends.

CAUTION

Do not allow the body to “cock” between the fl anges.
Valve must be centered on the fl anges.

4. Tighten the line bolting evenly and in small in cre­ ments to avoid uneven load ing of the seal retainer
(3) and seal retainer gas ket (9). See Ta ble 3 for

minimum and max i mum line bolt ing torques.

TABLE 3

Line Bolting Torques for Flangeless Bodies

Stud Size &

Thread UNC

Max. Torque

Ft-Lb.

Min. Torque

Ft-Lb.

1/2"-13 65 60

5/8"-11 120 100

3/4"-10 200 140

7/8"-9 320 160

1"-8 440 180

CAUTION

Do not torque line bolting beyond the limitations of
Table 3. Ref er ence the “Ranger-TB” for tem per a ture
range of Opt-7A alloy steel and Opt-7C SST line
bolting.

IOM-Ranger4

E. Packing Check:

1. Ensure that packing fl ange nuts (22) have not
worked loose during shipment.

2. For non-live loaded construction, hand tight en
the nuts (22) enough to stop any leakage. Do
not over tighten.

3. For live loaded construction, if spacer ring
(29) is loose, tighten both nuts (22) equally

until spacer ring (29) no longer “spins freely”

using two fi ngers. Rotate both nuts (22) ad-
di tion al 1/2 revolution for correct packing
load. See Figure 9 for correct orientation of
live-loaded packing design.

F. Insulation:

1. Insulate the valve body only. Do not insulate
the integral extension bonnet as this could
result in premature packing failure in low or
high temperature services. See Fig ure 3.

NOTE: The bon net of
in te gral ly fl anged bod-
ies should also not be
in su lat ed

IV. MAINTENANCE

A. General:

1. Maintenance procedures hereinafter are based
upon removal of the valve/actuator unit from
the piping where installed.

2. Owner should refer to owner’s procedures for
re mov al, handling and cleaning of non re us able
parts; i.e. gaskets, suitable solvents, etc.

3. Valves supplied from the factory do not use
any aid to assist in gasket sealing such as oil,
sealant or pipe dope.

4. Valves originally supplied per Opt-55 require
spe cial cleaning procedures. Refer to Cashco
Specifi cation No. S-1134 for details. When in

FIGURE 3:

Insulated Body

Flangeless Design

SECTION IV

compliance with/to Spec. No. S-1134, the
valve is suitable for oxygen service. This pro­ ce dure is limited to bodies of SST material

B. Trim Removal:

Access to the cage assembly with internal trim
pieces may be accomplished without removing
the actuator assembly (AA). Thus, it is not nec es­ sary to remove the pack ing set (13) or the stem
subassembly (7) to change internal trims. NOTE:

Plug (6) must be in the closed position to remove
the trim.

IOM-Ranger

5

1. Position valve on a fl at work sur face with the
actuator assembly (AA) oriented vertical.

NOTE: If actuator assembly (AA) has been
re moved, rotate stem (7) to close plug (6), and
proceed with Steps 4 through 8.

rod (10) be tween the lower case (2) and
the upper jam nut (43) to help se cure plug
in the closed position.

4. Remove the seal retainer screws (18) and
washers (23) and (47)

2. If the valve actuator includes a handwheel/ad­justing screw (58) assembly, use handwheel/
ad just ing screw (58) to remove the closing
torque; i.e. “stem windup”.

a. For ATO-FC valves: Loosen locking le ver/

nut (59) with CCW rotation when viewed
from above and rotate handwheel/ad just­ ing screw (58) CW just enough to relieve
the closing torque, but not enough to start
opening the plug (approximately 1/2-1
handwheel rev o lu tion).

b. For ATC-FO valves: Loosen locking le-

ver (59) with CCW rotation when viewed
from above and turn handwheel (58) CW
to fully close the plug (6) and then back
off enough to relieve the closing torque
by reversing the handwheel/adjusting
screw (58) CCW (approximately 1/2-1
handwheel revolution).

c. Remove machine screws (36) and cover

plate (20). Through opening in arm hous­ ing (4), insert a tool similar to a screw driv er
and apply force to either side at the lower
rod end (9). Rod end (9) will move easily
from side to side when all clos ing torque
has been relieved.

3. If the valve actuator does not include hand­wheel (58) assembly, connect a tem po rary
air supply with an in-line ad just able airset
reg u la tor with gauge to the ac tu a tor top works.
Remove machine screws (36) and cover plate
(20).

WARNING

Do not insert hands/fi ngers into body (1) or actuator
arm housing (4) openings while actuator is pressurized.

a. For ATC-FO Valves: Pressurize ac tu a tor

to a level 2-3 psig (0.1-0.2 Barg) under the
upper pressure lev el of the bench setting
as stated on the name plate (21); i.e. 5-15
psig (.34–1.03 Barg) range, set pressure
at 12-13 psig (.83-.90 Barg). Refer to 2.c.
previous to confi rm relief of all closing
torque. Ad just ac tu a tor pres sure slow ly
±1 to 2 psig (±.07–0.2 Barg) to con fi rm
great est/eas i est move ment of lower rod
end (9). Install slotted “C” wash er on push

5. Remove the seal retainer (3) (full or i fi ce, re-
duced, anti-cavitation, lo-noise), seal re tain er
gas ket (9), soft seal (10) (if supplied) and metal
seal (11).

6. Through backside of body (1), place a wood en
hammer handle on the vane on the back side of
the plug (6), or the LN2–LN4 lo-noise insert (25),
and tap lightly to remove cage as sem bly.

7. Remove bearings (4)( 5) from the cage (2).
(If necessary, pry or tap the bear ings loose.)
Rotate plug (6) 135° to 180° from the closed
position and lift plug (6) from the cage (2).

8. Remove abrasion sleeve (26) or LN2–LN4
lo-noise insert, if installed.

9. Depressurize actuator for ATC-FO valves.

C. Trim Reassembly:

Inspect and clean all parts. If any parts are worn,
replace with new parts. If the stem assembly (7) has
been removed, reassemble per Section IV, Sub sec­ tion F., then proceed to reassemble the trim.

For sizes 1" - 3", Reorient unit so that the back-end
of the body (1) is directed downwards, and the
front-end is up wards and in a horizontal plane. In
this position gravity will assist in proper alignment of
internals. For 4" - 8" sizes orient body on its side.

NOTES: A. The seal retainer gasket (9) and soft
seal (10) should always be replaced after every
dis as sem bly. Use only original factory re place­ ment parts.
B. For ATC-FO Valves without handwheel
(58) assembly: Pressurize ac tu a tor to levels in di­ cat ed per previous Sub sec tion 3.a. to prop er ly align
groove in stem sub as sem bly (7) to mate with the
tongue on the plug (6).

1. Install LN2/4 “lo-noise” insert (25) or “abra sion
sleeve” insert (26) into the body (1) cavity before
inserting the cage/plug subassembly (2)(4)(5)
(6). Ensure that the insert (25)(26) is properly
located within the groove located in the back­end of the body (1)

NOTE: For proper orientation of LN2, LN3 or LN4
trims, see Figure 6.

IOM-Ranger6

2. If at the body assembly (BA) level, ensure
that the stem sub as sem bly (7) is pulled back
into the bonnet of the body (1) so that the
stem (7) is in contact with the retainer sleeve
sub as sem bly (8).

3. Place plug (6) into cage (2). The ori en ta tion
must be such that the short stub shaft of the
plug (6) with the ma chined tongue extends
through the fl at side of the cage (2) toward
the stem (7). The plug (6) must be rotated
135° to 180° open before the plug (6) stub
shafts will slip into the cage's (2) bearing (4)
(5) slots. See fi gures 4 and 5.

5 Short Bearing

“Vane”
on back
side of
plug (6)

“Tongue” on plug (6) stub shaft, to en­gage with stem assembly (7) “groove”.

“Flat” on cage (2)

2

6

Short
Bearing

Seat Retainer

Plug rotated 180° from
closed position for dis as sem bly

Seal
Gasket

Tongue on
plug shaft

Cage

TFE Seal

Ring

Long Bearing

Inconel X-750
Seal Ring

Groove on stem

Valve Body

FIGURE 4: Quick Change Trim Parts

4. Slip bearings (4)(5) onto the plug (6) stub
shafts.

NOTE: Bearings (4) (5) are not the same length.
The shorter bear ing (5) fi ts the plug (6) stub shaft
that has the tongue end. See Figure 5.

5. Rotate plug (6) to the closed position. Ensure
that the plug (6) is fully pulled into the me­ chan i cal stop (5) on the cage (2). See Figure

7. Ensure that the closing torque is nil; i.e.
actuator assembly (AA) linkage is “loose” or
“slack”.

6. Insert the cage/plug subassembly (2)(4)(5)(6)
into the body (1). On 1-1/2" and 2" sizes with
lo-noise inserts or abra sion sleeve, make sure
these pieces and the cage (2) slip together
on the back of the cage (2). Make sure the
tongue on the plug (6) stub shaft and the
groove in the stem sub as sem bly (7) mate
to geth er. Check by look ing in through the
back-end of the body (1) or by ad just ing the
supply pres sure to the ac tu a tor within limits
of bench range as spec i fi ed on name plate
(21), watch ing for plug (6) move ment as stem
sub as sem bly (7) ro tates.

Shown with plug (6) in

4 Long Bearing

“closed” position

FIGURE 5

Back-end view of Cage/Plug Subassembly

Back-End

LN1 Trim

FIGURE 6

Lo-Noise Trim – LN2 through LN4

CAUTION

1. For ATC-FO Valve without handwheel (58) re move
slotted “C” washer from push rod (10) be tween lower
case (2) and the upper jam nut (43) before changing
supply pressure.

2. If the tongue and groove are not mated together, trim
parts could be damaged.

IOM-Ranger

7

Cage (2)

Mechanical
Stop

Plug (6)

Sizes 1", 1-1/2", 3", 6" & 8"
(DN25, 40, 80, 150 & 200)

Mechanical

Stops

Plug (6)

Sizes 2" & 4"
(DN50 & 100)

FIGURE 7

Mechanical Travel Stops - Plug in Closed Position

Front-End View

NOTE: All Sizes - Reorient unit so that the back-

end of the body (1) is directed downwards, and
the front-end is up wards and in a horizontal plane
so seals properly align on plug.

7. With plug (6) in the closed position, install the
metal seal (11) with cham fered edge of I.D.
to ward the plug (6); a note is “etched” on the
side of the metal seal (11) stating “TO WARD
PLUG”. Place seal re tain er gas ket (9) against
body (1) face and metal seal (11). Place soft
seal (10) against plug (6) face. See Figure 8
for as sem bly details.

NOTE: The soft seal (10) is not used with anti­cavitation trim (3) or with some trim des ig na tions.
In reverse fl ow di rec tion, the soft seal (10) is
ineffective.

Cage (2)

FIGURE 8:

Typical Seal Assembly

9. Install washers (23), belleville washers (47) (con­vex side up) and cap screws (18) and hand tighten.
Reduced port seal re tain ers (3) have re­ cess es ma chined-in to receive the washers
(23, 47). See Figure 17. These ensure that
the elon gat ed port (slot) is prop er ly aligned.
Wrench-tighten the cap screws (18) in 1/2
revolution in cre ments, in an alternating pat­ tern, until tight.

NOTE: The seal retainer gasket (9) and the soft
seal (10) are not “set” until the valve is placed in
the line and compressed between fl anges. If the
seals are “set” by clamping the valve between the
fl ang es during a seat leak age test, retighten the
cap screws (18) to hold the seal retainer (3) and
seals (9, 10 and 11) fi rmly in place. Once a soft
seal (10) is “set” by clamping the valve be tween
fl anges, it cannot be re moved, re in stalled and then
prop er ly centered to pro vide Class VI shutoff.

10. On ATO-FC and ATC-FO Valves with out
handwheel (58), replace cover plate (20)
and machine screws (36). De pres sur ize the
ac tu a tor for ATC-FO valves and dis con nect
tem po rary air sup ply.

11. Return to Section III.A. through F. for in stal­ la tion instructions.

8. Carefully set seal retainer (3) into position.
Vi su al ly check to see if the soft seal (10) is
centered over the metal seal (11), and that
the plug (6) is closed.

NOTE: To center the seals on the plug (6) face,
hold the seal retainer (3) against the as sem bled
trim parts with light hand pressure and rotate the
seal retainer (3) back and forth 90°, 3-4 times.
Spin 360° 3-4 revolutions.

D. Stem Removal:

CAUTION

The valve must be isolated from the process, all pres­ sures must be relieved and the unit removed from the
piping system before attempting disassembly.

IOM-Ranger8

1. Remove the actuator as sem bly (AA) from the
valve body as sem bly (BA). Refer to Ac tu a tor
main te nance manuals IOM-48 or 148.

2. Secure body (1) in a vise with the stem (7)
hor i zon tal to the fl oor. Place matchmarks
be tween yoke (12) and body (1) to assist in
fi nal orientation when re-assembled.

3. For live-loaded construction:

a. Loosen both packing fl ange nuts (22) until

clearance exists between the bot tom of
the nut (22) and the retainer (28).

b. Spacer ring (29) should “spin freely”. If

stacked mech a nism (27)(28)(29) is not
loose due to corrosion, debris, packed
dirt, etc., tap the spacer ring (29) lightly
while at tempt ing to pry up the spacer ring
(29) bottom with a thin fl at tool.

c. Remove both packing fl ange nuts (22)

only after the live-loaded mechanism (27)
(28)(29) is “free” and loose.

d. Pry up both live-loaded mechanisms (27)

(28)(29) one side at a time. Carefully lift the
mechanism (27)(28)(29) over the pack ing
stud (21) ensuring that the Belleville spring
washers (27) are not dropped in removal,
preventing a de ter mi na tion of washers'
(27) orientation one-to-the-oth er. Set
the two mech a nisms (27)(28)(29) down
together, side by side.

e. Inspect the retainers (28) for ori en ta tion.

Both of the retainers (28) should have
the same orientation. Improper/differing
ori en ta tions will cause un bal anced load­ing of the packing rings (13). See Figure
9 for proper ori en ta tion.

f. Inspect both spring washer (27) stacks

for proper orientation by carefully lifting
off the spacer ring (29) and retainer (28),
exposing the spring washer (27) stack.
Each stack of spring washers (27) should
be oriented the same. Improper/differing
orientation will cause unbalanced load ing
of the packing rings (13). See Figure 9
for proper orientation.

g. Replace all Belleville spring wash ers (27)

if there are any signs of corrosion. It is
recommended that spring washers be
replaced in full sets. The spacer rings (29),
retainers (28), as well as the packing studs
(21) should be re placed if corroded.

h. Remove yoke (12) bolting by removing

two cap screws (19) on 1", 1-1/2" and 2"
sizes, or two nuts (22) on the 3", 4", 6"
and 8" sizes.

Initial Setting
Position - TYP

Max
Wear

1" & 1-1/2" RANGERS ONLY

8 Spring Washers - Inverted Retainer

Ranger Live-Loaded Packing Design

i. Pull yoke (12), packing fl ange (14), pack ing

follower (15) and follower bushing strip
(16) off over end of stem (7). Re place pack­ing follower (15) if sig nifi cant ly cor rod ed.
Always replace fol low er bushing strip (16)
when of standard construction. (NOTE:

When Opt-38HT high tem per a ture pack­ ing is sup plied, the packing fol low er (15.1)
con tains a pressed-in car bon bush ing
(15.2) that is not fi eld re place able and
must be sup plied as a packing follower
(15) sub as sem bly.)

j. Loosen stem retainer screw (17) by ro tat-

ing CCW (viewed from above screw head)
2-3 rev o lu tions to check for trapped fl uid.
After all fl uid is vented, remove screw
(17).

k. Rotate stem (7) CW when viewed from

actuator end of stem (7) to close plug
(6).

l. Withdraw stem subassembly (7), retainer

sleeve subassembly (8) and packing set
(13) out of body (1).

NOTE: If diffi culty is encountered in re mov ing
the stem subassembly (7), use a puller as­ sem bly. See Figure 10. Hold the double nut
with a wrench to prevent rotation of the stem
as this could damage the seals if the trim is
still in the valve body (1). Use the single nut
to jack the stem sub as sem bly (7) out.

Maximum Wear Position

-Adjustment Required - TYP

Max

Wear

2", 3" & 4" RANGERS ONLY

6 Spring Washers

Non-Inverted Retainer

FIGURE 9

Max Wear

0.050"-0.060"

- TYP

28

Max Wear

29

2

1

IOM-Ranger

9

DIMENSIONS

Valve A B C D E F G
Size (Pipe Size) (O.D.) (I.D.) (Thd Rod)
1", 1-1/2," 3/4" 7-13/16" 1-1/4" 5/16" 3/16" 1/4"-28 4"
2"
3", 4" 1-1/2" 11-13/16" 2-1/8" 7/16" 1/4" 3/8"-24 4-1/2"
6", 8" 2-1/2" 9-3/16" 3-1/8" 7/16" 1/4" 3/8"-24 4-1/2"

FIGURE 10: Stem Puller

4. For Non-Live-Loaded Packing Con struc tion:

a. Remove two packing flange stud nuts

(22) and two cap screws (19) on the 1",
1-1/2" and 2" sizes, or four nuts (22) on the
3", 4", 6" and 8" sizes.

b. Pull yoke (12), packing fl ange (14), pack ing

follower (15) and follower bushing strip (16) off
over end of stem (7). Re place packing follower
(15) if sig nifi cant ly cor rod ed. Always replace
fol low er bushing strip (16) when of standard
construction.

c. Proceed with previous steps 3.j. through 3.q.

for stem removal.

m. Using a suitable solvent acceptable to the owner,

thoroughly clean the valve stem (7) and the
body's (1) stuffi ng box. Inspect surface fi nish of
stem sub as sem bly (7) and internal wall fi nish of
packing box bore at packing (13) area. If deeply
scratched, corroded or pit ted, re place with new
parts.

n. It will be desirable to restore the surface of

the body's (1) stuffi ng box to 16 mi cro-inch Ra
fi nish; metal removal should not exceed 0.001
inch ma te ri al.

o. It will be desirable to restore the sur face of the

stem's (7) critical area to 6–8 micro-inch Ra fi n-
ish or better, metal re mov al should not exceed

0.001 inch ma te ri al. Minimum stem OD should
not be less than indicated in Table 4.

p. Remove retainer sleeve sub as sem bly (8) from

stem subassembly (7). Ex am ine carbon bush­ing insert of re tain er sleeve subassembly (8)
for dam age or signs of wear. Replace re tain er
sleeve sub as sem bly (8) if worn more than 0.005
inch (0.13 mm). See Figure 12 for indicated
di men sion “X”.

E. Stem Reassembly – Trim Retained in Body:

1. Slide retainer sleeve subassembly (8) onto
the stem subassembly (7), with the car bon
bushing (8.2) end against the shoul der of the
stem subassembly (7).

NOTE: For Slurry Trim see Subsection H.

2. Insert the stem/retainer sleeve (7)(8) as sem­ bly into the body (1), aligning the hole in the
retainer sleeve (8) to be directly in line with
the thread ed hole in the body (1) bonnet.
Align the stem sub as sem bly (7) so that the
plug’s (6) tongue and the stem's (7) groove
will engage.

NOTE: A small "fl at" area has been milled on the
stem and for correct engagement this "fl at" must
be on the same side as the face of the plug (6).

CAUTION

CAUTION

The tongue and groove connection between the stem
subassembly (7) and the plug (6) can cause me chan i cal
damage or disengagement if the carbon bushing in sert
is worn.

q. Examine packing studs (21) and nuts (22).

Replace if signs of corrosion are present.

TABLE 4 - STEM O.D.

Body Size Minimum Stem O.D.

1", 1-1/2" & 2"

(DN25, 40 & 50)

3" & 4"

(DN80, 100)

6" & 8"

(DN150, 200)

.620

.995

.995

Do not hammer on end of stem. Potential exists to
cause damage to the tongue and groove connection
or to the seals.

3. Visually confi rm alignment of hole in re tain er
sleeve (8.1) with threaded hole in body (1)
bonnet. Place thread sealant Cotronic Res­bond 907, or equal, on stem retainer screw
(17) threads for valves used in non-oxygen
service; thread sealant to be Oc ci den tal
Petroleum Corp. Fluorolube GR-362, or
equal, for valves used in oxygen service.
Insert and tight en stem re tain er screw (17)
20-25 ft# (27-34 N-M) for 1"– 2" sizes,
80-85 ft# (108-115 N-M) for 3"– 8LF" sizes
and 90 ft# (122 N-M) for 8"HF size.

4. Rotate stem (7) to ensure tongue and groove
engagement with plug (6).

IOM-Ranger10

5. Proceed to Subsection G. for installation of
pack ing (13).

F. Stem Reassembly – Trim Removed from Body

1. Install retainer sleeve subassembly (8) and
stem subassembly (7) in ac cor dance with
Subsection E, Ar ti cles 1 through 3, pre vi ous.
Rotate stem (7) to plug's (6) closed po si­ tion.

2. Install trim in accordance with Subsection C,
Ar ti cles 1 through 10, previous.

3. Install packing in accordance with Sub­ section G.

G. Packing Replacement:

Remove stem as per Subsection D. previous and
pro ceed as follows.

1. Secure body (1) in a vise with stem (7) verti­cal to the fl oor. Reassemble stem (7) per
ap pro pri ate Subsection E., F., or H.

Standard TFE

V-ring Packing Stack

Opt-38HT High Temp.

Packing Stack

Packing Stack Orientation

Opt-38V Vaccum Service

V-ring Packing Stack,

For 1", 1-1/2" & 2" body
sizes use ONLY 2 packing
rings (13.2)

For 3", 4", 6" & 8" body
sizes use 3 packing rings
(13.2)

FIGURE 11

2. Never replace packing (13) without re con­ di tion ing the stem (7) surface fi nish and the
body (1) stuffi ng box as specifi ed in Sub sec tion
IV.D.

3. For TFE V-Ring Packing. (See Figure 11.)

NOTE: Following text pertains to “stan dard”
pack ing stack (13) orientation. Stack procedures
differ slightly for other packing options. See Fig­ure 11.

a. Remove packing follower bushing strip

(16). Solvent clean packing follower (15).
Insert new packing follower bushing strip
(16). Ensure no overlap of strip (16).

b. Carefully place lower adapter (13.1) of

packing ring set (13) over stem's (7) end,
properly oriented (see Figure 11). Using
the packing follower (15), push the adapt er
(13.1) into the body's (1) stuffi ng box.

c. Carefully install the fi rst individual V-ring

(13.2) over stem's (7) end, properly ori­ ent ed. Push down as far as possible using
fi n gers. Carefully place each ring (13.2)
upon the other until all V-rings (13.2) are
stacked, properly oriented.

d. Place upper adapter ring (13.3) over the

stem's (7) end, properly oriented.

e. Place the packing follower (15) over the

stem (7) end, properly oriented, until
sit ting on the upper adapter ring (13.3).

Push down on the packing follower (15)
using fi ngers; all V-rings (13.2) and upper
adapter (13.3) should easily slide into the
body (1) stuffi ng box.

NOTE: It will be necessary to pull up on

the stem (7) as the adapters (13.1, 13.3)
and packing rings (13.2) are “pushed” into
the stuffi ng box.

f. For body sizes 1", 1-1/2" & 2":

f.1. Slide both yoke (12) and packing

fl ange (14) over end of stem (7), prop­ er ly ori ent ed, and over pack ing studs
(21). Align matchmarks be tween body
(1) and yoke (12).

f.2. Install two cap screws (19) to as-

sem ble the yoke (12) to the body (1)
securely.

g. For body sizes 3", 4", 6" & 8":

g.1. Slide yoke (12) over end of stem (7),

properly oriented, and over packing
studs (21). Align matchmarks be­ tween body (1) and yoke (12).

g.2. Slide packing fl ange (14) over end of

stem (7), properly oriented, and over
pack ing studs (21).

g.3. Install two nuts (22) on studs (20) to

assemble the yoke (12) to the body
(1) securely.

h. Proceed to Article 6 for Opt-38 Jammed

Pack ing.

IOM-Ranger

11

With Externally Live-Loaded Construction
pro ceed as follows:

i. Place each spring washer (27) stack over

its packing stud (21) oriented as shown
in Figure 9.

j. Place each spacer ring (29) over its pack-

ing stud (21) and spring washer stack (27)
oriented as shown in Figure 9.

k. Place each retainer (28) over its packing

stud (21) oriented as shown in Figure 9.
Ensure that each retainer (28) is properly
positioned into each spacer ring's (29)
groove, and that the retainer's (28) in ver­ sion is correct.

l. Proceed to Article 5. , this Subsection.

4. For Opt-38HT High Temp Packing:

a. Solvent clean the packing follower (15).
b. Carefully place the lower braided ring

(13.4) over the stem's (7) end. Using the
packing follower (15) push the braided
ring (13.4) into the body's (1) stuffi ng box.

NOTE: It will be necessary to pull up on
the stem (7) as the rings (13.2, 13.4) and
lower adapter (13.1) are “pushed” into the
stuffi ng box.

c. Carefully place the lower adapter (13.1)

properly ori ent ed (see Figure 11) over the
stem's (7) end and push into the stuffi ng
box similar to the lower braided ring (13.4)
of Step 4.b.

d. Carefully place a packing ring (13.2)

prop er ly oriented (see Figure 11) over the
stem's (7) end and push into the stuffi ng
box similar to the lower braided ring (13.4)
of Step 4.b. Repeat for each ring (13.2).

e. Carefully place the upper adapter (13.3)

similar to the lower retainer (13.1) of Step

4.b. Leave packing follower (15) in po si­ tion, properly oriented.

f. Place the packing fl ange (14) over the

stem's (7) end and over the packing studs
(21). Place the retainer (28) over each
stud (21). Install packing nuts (22) and
fi nger-tighten.

g. Wrench-tighten the packing nuts (22) in

1/2 revolution increments until the “upper
groove” identifi ed as “Line A” (see Figure

13) on the packing follower (15) is fl ush
with the top edge of the body's (1) stuffi ng
box.

h. Remove the packing nuts (22), retainers

(28), packing follower (15) and packing
fl ange (14).

i. Carefully place the upper braided ring

(13.5) over the stem's (7) end and push
into the stuffi ng box similar to the lower
braided ring (13.4) of Step 4.b. Leave
packing follower (15) in position.

j. Place the packing fl ange (14) over the

stem's (7) end and over the packing studs
(21). Place the retainers (28) over each
stud (21). Install packing nuts (22) and
fi nger-tighten.

k. Repeat Step 4.g. with the exception that

the packing set (13) is to be compressed
into the stuffi ng box until the “lower groove”
identifi ed as “Line B” (see Figure 13) on
the packing follower (15) is fl ush with the
top edge of the body's (1) stuffi ng box.

l. Remove the packing nuts (22), retainers

(28) and packing fl ange (14).

m. For body sizes 1", 1-1/2" & 2":

m.1. Slide both yoke (12) and packing

fl ange (14) over end of stem (7),
prop er ly ori ent ed, and over pack­ ing studs (21). Align matchmarks
be tween body (1) and yoke (12).

m.2. Install two cap screws (19) to as-

sem ble the yoke (12) to the body
(1) securely.

n. For body sizes 3", 4", 6" & 8":

n.1. Slide yoke (12) over end of stem (7),

properly oriented, and over pack­ing studs (21). Align matchmarks
be tween body (1) and yoke (12).

n.2. Slide packing fl ange (14) over end

of stem (7), properly oriented, and
over pack ing studs (21).

n.3. Install two nuts (22) on studs (20) to

assemble the yoke (12) to the body
(1) securely.

o. Place each spring washer (27) stack over

its packing stud (21) oriented as shown
in Figure 9.

p. Place each spacer ring (29) over its pack-

ing stud (21) and spring washer (27) stack
oriented as shown in Figure 9.

q. Place each retainer (28) over its packing

stud (21) oriented as shown in Fig ure 9.
Ensure that each retainer (28) is properly
positioned into each spac er ring's (29)
groove, and that the retainer's (28) in ver­ sion is correct.

5. Common For All Live-Loaded Designs:

a. Install packing nuts (22) fi nger-tight down

to each retainer (28).

IOM-Ranger12

b. Draw down each packing nut (22) in

al ter nat ing 1/2 revolution increments,
check ing each spacer ring (29) after each
tight en ing. When spacer ring (29) can no
long er be rotated freely by fi ngers, make
an ad di tion al 1/2 revolution – no further
tight en ing should occur to main tain the
“live-loaded” intent of the design. Over­ tight en ing of the design as de scribed
caus es the mechanism to func tion as
a “jammed pack ing. This will de feat the
design intent of the mech a nism and will
increase packing (13) wear.

c. Refer to Actuator Maintenance Man u als

IOM-48 or 148 to reconnect ac tu a tor/arm
housing (AA) to yoke (12).

6. Common to Opt-38J Jammed Packing
Only:

NOTE: Packing follower (15) must penetrate into
the stuffi ng box of the body (1).

a. Install nuts (22) on packing studs (21) and

fi nger tighten.

b. Refer to Actuator Maintenance Man u als

IOM-48 or 148 to reconnect ac tu a tor/arm
housing (AA) to yoke (12).

c. Tighten packing nuts (22) to torque levels

indicated in Table 5.

H. Slurry Trim – Opt-AS:

1. Install the trim in the body (1) per Section IV,
Sub sec tion C, Articles 1 through 10.

2. Slide retainer sleeve subassembly (8) onto
the stem assembly (7) with the stem retainer
carbon bushing (8.2) end against the stem
(7) subassembly shoulder.

3. Apply lubricant (silicon grease or equiv a lent)
to O-ring (30), and slide backup ring (31) and
O-ring (30), re spec tive ly, into groove on stem
(7) groove-end. See Figure 21 for O-ring (30)
orientation.

4. Insert the stem/retainer sleeve (7)(8) as sem­ bly into the body (1), aligning the hole in the
retainer sleeve (8) to be directly in line with
the thread ed hole in the body (1) bonnet.
Align the stem sub as sem bly (7) so that the
plug’s (6) tongue and the stem's (7) groove
will engage. Insert as sem bly.

CAUTION

If O-ring (30) on stem subassembly (7) is inserted into
the body (1) cavity and then pulled back into the bonnet,
the O-ring (30) may be damaged.

Table 5

Packing Nut Torques

Body Size

1",1-1/2", 2"

(DN25, 40, 50)

3", 4"

(DN80, 100)

6" & 8"

(DN150, 200)

NOTE: When valve is returned to operation, check
for leakage and tighten the nuts (22) evenly in
alternating 1/4 revolution in cre ments until leak age
stops. DO NOT OVERTIGHTEN.

Torque

in-lbs. N-M

50 67

130 176

165 223

NOTE: A small "fl at" area has been milled on the
stem and for correct engagement this "fl at" must
be on the same side as the face of the plug (6).

5. Visually confi rm alignment of hole in re tain er
sleeve (8.1) with threaded hole in body (1)
bonnet. Insert and tighten stem re tain er screw
(17).

6. Rotate stem (7) to ensure tongue and groove
engagement with plug (6).

7. Proceed to Section IV, Subsection G. for
in stal la tion of packing (13).

J. Pressure Test:

1. Cashco recommends that a pressure integrity
test be performed following reassembly when
the pack ing set (13) has been replaced.

IOM-Ranger

13

SECTION V

V. STARTUP

A. General:

1. Ensure that the Ranger QCT unit has been
properly adjusted and calibrated, including
the positioner if installed, per actuator main­ te nance manuals IOM-48 or 148.

2. Recommend startup to be in “manual” mode.
This procedure assumes double block (iso­ la tion) and bypass valves for the “control valve
station”. See Figure 1.

3. Start with one of the two block valves closed,
with the other open. The bypass valve should
be closed. Pressurize system if possible/
prac ti cal.

4. Back out the airset's adjusting screw until
loose.

5. Turn on air supply pressure.

6. Adjust the air supply airset (fi lter-regulator)
to the proper level as indicated on the unit's
nameplate (20), in IOM-48 or IOM-148, or
the tech ni cal bulletin Ranger-TB. DO NOT
STROKE THE CONTROL VALVE WITH
AN AIR SUPPLY PRES SURE SETTING
GREAT ER THAN REC OM MEND ED MAX I­ MUM PRESSURE!

7. Place loop controller into “manual” mode. Vary
setting from minimum – mid-range — maxi­mum SIG output. Observe response of control
valve unit to these changes of input SIG. The
valve should fully stroke at the variation from
minimum SIG to maximum SIG; the mid-range
SIG should have the valve stem travel at/near
1/2 open.

8. Confi rm that action of controller and po si tion er
– direct or reverse – are producing the desired
response in the control unit. Confi rm that the
control valve “fail” position is as re quired.

9. Hereafter, the procedure assumes that actual
fl uid fl ow may be established. This may not
be practical/possible in all cases; if so, vary
pro ce dure as required.

Always “heat” or “cool” down the system pip ing

SLOW LY by opening the control valve station
bypass valve in small in cre ments.

WARNING

DO NOT WALK AWAY AND LEAVE A MANUALLY

CONTROLLED CONTROL VALVE UN AT TEND ED!

10. With one of the control valve station block
valves still closed, and the loop controller
still in “manual” mode, open bypass valve
and vary fl ow rate manually to observe the
re sponse of the controller and control valve
unit together.

11. Attempt to develop manual control of the loop
by opening/closing the manual bypass as re­quired, or by manually controlling main stream
fl ow as required.

12. When the control valve is partially open, slow ly
crack open the closed block valve while si mul ­ta neous ly closing the bypass valve; it may be
necessary/desirable to vary the manual out put
SIG from the controller simultaneously also.
Continue this pro ce dure until the bypass is
closed and the block valves are both fully open.
The system is still under “manual” mode con­trol, but all fl ow is passing through the control
valve.

13. Vary controller “manual” SIG output until
match ing the “automatic” SIG output, then
change the mode of the controller over to
“automatic”, and the loop will experience a
minimum of upset conditions, and will be in
automatic control.

IOM-Ranger14

SECTION VI

VI. TROUBLE SHOOTING GUIDE

The information that follows is specifi c to address prob lems related to the valve body assembly. Refer to the Rotary
Actuator Maintenance Manual IOM-48 or 148 for issues related to valve travel, bench range, calibration, etc.

1. Valve is “jumpy” in stroking.

Possible Cause Remedy

A. Excess packing friction.

B. Stem seized due to corrosion/buildup of scale. B1. Disassemble valve and remove buildup. Give

C. Feedback linkage is bent; cam follower worn. C1. Replace feedback linkage and character cam.

D. Actuator spring problems. D1. Broken spring. Replace all springs.

2. Valve exhibits “excess” vibration.

Possible Cause Remedy

A. Excess pressure drop. A1. Bring pressure drop within design limits.

B. Excessive cavitation in liquid service. B1. Change fl ow conditions, if possible.

C. High Outlet Noise Level C1. Reduce pressure drop, if possible.

A1. Once packing is overtightened, the valve must
be removed from operation and pressurization,
packing removed, and new packing installed.
A2. Install positioner.

consideration to installing slurry trim option.
B2. Consider stem purge.

C2. Ensure alignment between cam in arm housing
and feedback linkage is centered.
C3. Ensure that the carbon bushing of the stem re­ tainer subassembly has not worn and allowed
the stem to move outward along its axis. If
bushing wear seems premature, consider re­ placing with stellite bushing over carbon.
C4. Arms are not tightly clamping to the stem.
Tighten bolt/nut securing arms.

D2. Non-symmetrical positioning of springs; ensure
that springs are symmetrical; i.e. springs 180°
across from each other.

A2. Stage pressure drop using multiple valves in
series.

B2. Increase back pressure on valve's outlet using a
downstream restriction.
B3. Place a restriction upstream of the control valve.
B4. Do both B2 and B3.
B5. Consider use of anti-cavitation seal retainer;
reverse fl ow direction required.
B6. If standard fl ow direction, reverse fl ow direction.
B7. Cool the liquid.
B8. Use multiple valves in series.

C2. Reduce fl ow rate, if possible.
C3. Install lo-noise trim, 1-stage or 2-stage.
C4. Split fl ow into two parallel streams with two
control valves.
C5. Stage pressure drop using two control valves in
series.
C6. Place a restriction downstream of the control
valve.
C7. Place a restriction upstream of the control valve.
C8. Do both C6 and C7.
C9. Noise trim worn/damaged; replace lo-noise trim.
C10. Trim wear; replace trim.
C11. Install fl uorocarbon elastomer spacer if there is a
“slot” for soft seal in retainer, but no seal is
installed.

IOM-Ranger

15

3. Valve exhibits “excess” seat leakage.

NOTE: The Ranger QCT incorporates both a metal seal and a soft seal in many trim designs. For some options
and trim designs the soft seal is omitted. Soft seals are never used in “reverse” fl ow direction.

Possible Cause Remedy

A. Valve stroke limited mechanically. A1. Loosen locking lever (59) and rotate

handwheel (58) CCW to its positive up-stop
position. Retighten lock ing lever.
A2. Properly adjust actuator up-stop washer.

NOTE: DO NOT ADJUST THE ACTUATOR
JAM NUT (45) AND STOP SCREW (35).

B. Improper actuator bench setting. B1. Calibrate actuator to valve.

B2. Ensure proper engagement of push rod
linkage from actuator to valve stem.

C. Excess trim wear. C1. Erosive service, remove particulate from

services.
C2. Use “ST6” trim designation numbers; fl ow to
be in “reverse” direction.
C3. Possible excess cavitation in liquid service.
Change operation parameters.
Use anti-cavitation trim.
C4. Incorporate trim using fl uorocarbon elastomer
spac er.
C5. Install abrasion sleeve.

D. Soft seal leakage D1. Erosive service; remove particulate from

services.
D2. If steam pressure exceeds 150 psig, switch to
ST7 trim designation number.
D3. If T1 is greater than 400°F, switch to trim
designation number S7.
D4. Valve travel restricted; plug not “pulling into”
cage stops.
D5. Wrong fl ow direction. Soft seal ONLY effective
in standard/forward fl ow direction.
D6. Insuffi cient ∆P. Soft seal is pressure ener-
gized.

E. Metal seal leakage E1. Damaged seal due to debris in fl ow stream.

Replace seal.
E2. Over-temperature of soft seal; soft seal
deforms over edge of metal seal ring.
Remove soft seal or switch to trim designation
number ST7.
E3. Install fl uorocarbon elastomer spacer if no soft
seal is installed.
E4. Valve travel restricted; plug not “pulling into”
cage stops.
E5. Erosive wear. Replace seal.
E6. High velocity. Check sizing for velocity & noise.

IOM-Ranger16

4. Premature Packing Leakage.

Possible Cause Remedy

A. Over-temperature. A1. Remove insulation along body to allow direct

contact with ambient air.
A2. Replace standard packing with high-temp.
packing - re quires positioner.

B. Improper packing orientation. B1. Ensure correct stack up of packing pieces.

B2. Determine if packing is being exposed to a
vacuum at any time. Consult factory if vacuum
is occurring.

C. Insuffi cient force/packing follower loose. C1. Tighten packing follower/nuts to indicated

dimension per Section 8. Replace with new
packing assembly as necessary.
C2. Replace packing spring washers if corrosion is
obvious.

D. New valve installed at operating pressures
and temperatures.

5. Seal Retainer/Flange Leakage

Possible Cause Remedy

A. Improper pipe supports and anchors. A. Provide piping anchors and guides at control

B. Incorrect line bolting. B. Use high strength line bolting heat treated alloy

C. Flange bolting unevenly loaded. C1. Loosen and remove line bolting, replace fl ange

D. Incorrect seal retainer gasket material. D. Remove seal retainer gaskets and replace with

E. Corrosion E. Consult factory.

D. Adjust per Section III, Subsection E.

valve station. Restrain bending movements.

steel (Opt-7A) or corrosion resistant SST
strainer hard ened studs (Opt-7C).

gasket and reinstall fl ange bolting. See Table
3, Section III, for line bolting torques.
C2. Valve used to “pull” pipe into alignment. Loosen
bolting, properly align pipe and retighten bolting.

factory supplied fl exitallic gaskets.

6. Insuffi cient Capacity.

Possible Cause Remedy

A. Wrong valve size. A. Recheck original sizing conditions with actual

calculated Cv and install new trim pieces or
complete valve as necessary.

B. Seal retainer too small. B. Change seal retainer size in accordance to Cv

calculations.

C. Improper actuator bench setting. C. Calibrate actuator to valve for 90° travel.

IOM-Ranger

17

7. Valve does not respond to changes in signal.

Possible Cause Remedy

A. Improper control action(s). A1. Disconnect signal to actuator to determine

control valve action.
A2. Determine controller output action.
A3. Determine positioner output action.

B. Plug tongue and stem grove not engaged.
Carbon bushing insert in retainer sleeve
assembly is worn.

B1. Replace carbon bushing insert.
Refer to Figure 2 for critical dimension.
B2. Consider change to stellite bushing.

C. Damaged positioner linkage. C. Inspect linkage. Replace if necessary.

D. Damaged actuator stem linkage. D. Replace linkage. Ensure not overpressuring.

E. Plug bearings not properly fi tted during
reassembly

E. Reinstall bearings – shorter bearing fi ts plug
shaft that has tongue milled on it.

F. Plug tongue and stem groove connection F. Replace both stem and plug. Determine cause

of this failure prior to reassembly.

SECTION VIII

VIII. ORDERING INFORMATION
NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on
the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"),
a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code
typical format as follows: (last digit is alpha character that refl ects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen­ ta tive with the Serial Number and Product code.
With this information they can provide a quotation
for a new unit including a complete description,
price and availability.

CAUTION

Do not attempt to alter the original construction of any
unit without assistance and approval from the factory. All
purposed changes will require a new name plate with ap­propriate ratings and new product code to accommodate
the recommended part(s) changes.

–

7

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen­ ta tive with the Serial Number and Product code.
Identify the parts and the quantity required to repair
the unit from the "BOM" sheet that was provided
when unit was originally shipped.

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” refl ect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".

If the "BOM" is not available, refer to the cross­sectional drawings included in this manual for part
identifi cation and selection.

A Local Sales Representative will provide quotation
for appropriate Kit Number, Price and Availability.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be con­strued as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify
or improve the designs or specifi cations of such product at any time without notice.
Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Cashco, Inc. product remains solely with the purchaser.

IOM-Ranger18

13

15.2

15.1
“Line A”

“Line B”

Critical
Finish
Area

15.1

27

21

22

29

15

16

17

8

13

12

14

28

7

8.1

7

Critical

Fini sh

Zone

"X"

Body
Size

"X"

Dimension

1"-2"

.022

3"-6"

.040

1

8.2

Line A

Line B

Item No. Part Description Item No. Part Description
1 Body 15 Packing Follower
7 Stem Subassy. 16 Follower Bushing Strip
8 Stem Retainer Subassy. 17 Stem Retainer Screw

8.1 Retainer Sleeve 21 Packing Stud

8.2 Carbon Bushing 22 Packing Stud Nut
12 Yoke 27 Belleville Spring Washers
13 Packing Ring Set 28 Retainer
14 Packing Flange 29 Spacer Ring

IOM-Ranger

Ranger Live-Loaded Packing Design

FIGURE 12

Item No. Part Description
14 Packing Flange
15 Packing Follower Assy.

15.1 Follower

15.2 Carbon Bushing

FIGURE 13

Ranger Live-Loaded Packing with Opt-38HT

High Temperature Packing Design

19

3", 4", 6" & 8"

YOKE

Front-End

Back-End

BA – Body Assembly - Side View -

Std. Flow Direction

Item No. Part Description

1 Body
2 Cage
3 Seal Retainer
4 Bearing (Long)
5 Bearing (Short)
6 Plug
7 Stem Subassembly
8 Retainer Sleeve Subassembly
9 Seal Retainer Gasket
10 Seal (Soft)
11 Seal (Metal)
12 Yoke
13 Packing Ring Set
14 Packing Flange
15 Packing Follower
16 Follower Bushing Strip
17 Stem Retainer Screw
18 Hex Head Cap Screw (Seal
Retainer Screw)
19 Hex Head Cap Screw (1",
1-1/2", 2" Ranger & 8'HF Ranger)
20 Stud (Short) (3", 4", 6", 8" Ranger)

Integral Flanged

Flangeless

BA – Body Assembly - Front View

Item No. Part Description

21 Stud (Packing Flange)
22 Nut (For Short Studs & Packing
Flange Studs)
23 Washer
24 Cap Screw (For Mtg. to Actuator)
25 Low Noise Insert
26 Abrasion Sleeve
27 Washer (Belleville)
28 Retainer (Washer)
29 Spacer (Live Loaded Packing)
30 O-Ring
31 Backup Ring
32 Tie Bolt
33 Nut (used with Tie Bolt)
43 Drive Screw (Flanged Ranger)
44 Flow Arrow (Flanged Ranger)
45 Security Seal
46 “Caution” Plate
47 Belleville Washer
48 Stem Retainer Screw Gasket

FIGURE 14

Body Assembly

IOM-Ranger20

FIGURE 15

1", 1-1/2" & 2" Yoke

Recess for washer (23)

NOTE: Seat retainer slot axis
is always per pen dic u lar to
stem axis.

FIGURE 16

Anti-Cavitation Seal Retainer or

LNA/D Lo-Noise Seal Retainer

Centerline of valve

stem (7)

FIGURE 17

Reduced Trim Seal Retainer

FIGURE 18

Abrasion Sleeve

FIGURE 19

LN2 – LN4 Lo-Noise Insert

IOM-Ranger

21

FIGURE 20

Ranger Control Valve Line Bolting

FIGURE 22

Jammed Packing

* Used with 1-1/2"-8" AT1, AT2 & AT4 Trim

FIGURE 21

Slurry Trim

*

“C” Washer
installed

FIGURE 23

ATC-FO Actuator less Handwheel Assy.

IOM-Ranger22

NOTES

IOM-Ranger

23

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [e-mail]

Printed in U.S.A. Ranger-IOM

Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [e-mail]

Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [e-mail]