R

High Performance Butterfly Valve INSTRUCTION MANUAL

304YA

Contents Page
FOR YOUR SAFE USAGE 1
1. PRODUCT FEATURES 2
1. 1 About the Product 2
1. 2 Standard Specifications 2
1. 3 Pressure - Temperature Rating 3
2. STRUCTURE 4
2. 1 Expanded View and Part List 4
3. PRECAUTIONS FOR USE 5
3. 1 Safety Measures 5
3. 2 Transportation and Storage 6
3. 3 Installation and Working Environment 7
3. 4 Installation Precautions 9
3. 5 Precautions for Safe Handling After Installation 12
3. 6 Maintenance 13
4 INSTALLATION 15
4. 1 Installation Procedure 15
5 MAINTENANCE 17
5. 1. Seatring Disassembly/Assembly Procedures 17
5. 2 Removal of Valve Body and Actuator 18
5. 3 Disassembly/Assembly Procedures of Gland area 19
5. 4 Assembly Procedure of Valve Body and Actuator 20
5. 5 Valve Body Full-Close Position Adjustment Procedure 21
6. Piping Data 22
6. 1 Minimum Inner Pipe Diameter and Disc
22
Protruding Dimension at Full-open Position
6. 2 Applicable Pipes 22
6. 3 Piping Gasket Dimensions 23
6. 4 Piping Bolt Sizes 24
7. TROUBLESHOOTING 25
7. 1 Troubleshooting 25
WARRANTY PERIOD / SCOPE OF WARRANTY
AND INDEMNITY / CHARGED REPAIR SERVICE
AND SUPPLY OF DISCONTINUED PARTS / 28
REPLACEMENT TIMING OF SPARE PARTS /
APPLICABLE APPLICATION CONDITIONS
 FOR YOUR SAFE USAGE　The following instructions should always be followed.
Thank you for purchasing our products.
For safe use of our products over long periods of time, please read this instruction manual (here-
inafter "this document") thoroughly before use, and use the products properly in accordance
with the contents.
The following instructions are for long-lasting service of High Performance Butterfly Valve 304YA
(hereinafter "this product") without loss or injury.

■ In this document, the level of danger or damage caused by neglecting these cautions
will be indicated as follows:

WARNING This mark indicates "possibility of death or serious injury".

This mark indicates "possibility of injury to personnel or physical damage

CAUTION only".

■ In this document, the following marks will indicate particular points for your attention.

This mark indicates items that "you must not do".

This mark indicates items "you must do".

■ Requests
⿟⿟Be sure to read this document before carrying out transportation, storage, piping installation, operation and main-
tenance work.
⿟⿟This document does not describe all the assumed conditions concerning transportation, storage, piping installa-
tion, operation and maintenance of this product. If you have any questions, please contact our sales department.
⿟⿟Reference values and limit values for operation, maintenance and inspection specified in this document have
been determined in consideration of maintenance management of this product. This product should be used
within the range of the reference values and the limit values.
⿟⿟This product should be used only with the dedicated actuator installed when shipped. Do not use this product
with other actuators.
⿟⿟Be sure to store this document in a readily accessible place for future reference after installation and start of
operation. When a staff in charge is changed, information on the storage place of this document and operation
should be communicated to the next staff.
⿟⿟If this product gets dented or scratched on impact, to ensure safety stop use of the product and replace it.
⿟⿟Details of this document are subject to change without notice.

1
1. PRODUCT FEATURES
1. 1 About the Product
This product is a double eccentric butterfly valve, which controls fluid by 90-degrees rotation of the disc.
The valve can be fully opened or closed. In addition, an intermediate valve opening can be used for fluid control.

1. 2 Standard Specifications
<Table-1> 304YA Standard Specifications
Valve Model 304YA
Valve Type Double eccentric (Wafer)
1 1/2, 2, 2 1/2, 3, 4, 5, 6, 8, 10, 12inch
Valve nominal size
40, 50, 65, 80, 100, 125, 150, 200, 250, 300 mm
Max. allowable working pressure 1.0 MPa
Allowable seat leakage standard ISO 5208 leakage rate A (tight shut-off)/ JIS B 2003-2013 rate A
Flow direction Retainer side pressurization
Face to face
JIS B 2002-1987 (series 46)/ ISO 5752 wafer butterfly valve (short)
dimensions
Applicable
Applicable flange
standards JIS 5K / JIS 10K / ASME / ANSI CLASS 150
connection
Top flange In compliance with ISO 5211
Body SCS13A FCD450
Disc SCS13A
Standard
Shaft SUS630 SUS420J2
materials
Seatring RPTFE (Carbon and graphite contained)
Gland packing RPTFE (Graphite contained)
Maximum temperature range -29°C - 200°C -20°C - 200°C
1T -20°C - 80°C
2U -10°C - 80°C
Ambient temperature range 7E, 7F, 7G -10°C - 60°C
3U, 3K 0°C - 80°C
4I ,4J -10°C - 50°C
Body Shell Working pressure × 1.5 (Water pressure)
Test pressure
Seat leakage Working pressure × 1.1 (Pneumatic pressure)
Lock Lever 1T 40 mm - 150 mm
Worm gear 2U 40 mm - 300 mm
7E 40 mm - 300 mm
Actuator
Pneumatic cylinder 7F, 7G 40 mm - 200 mm
3U, 3K 250 mm, 300 mm
Motorized 4I ,4J 40 mm - 300 mm
Maximum average flow velocity
6 m/s or less (Valve full-open, continuous operation)
in piping (Limit value)
Body color FCD450-body only : Modified silicon resin coating Munsell N7 (Gray)

2
 1. 3 Pressure - Temperature Rating

Pressure [MPa]
1.0

0.8

0.6 Case of FCD450-body :

-4°F or over ~ less than 392°F

Case of SCS13A-body :
0.4
-20°F or over ~ less than 392°F

0.2

-29 -20 0 50 100 150 200 250

Temperature [℃]
[Fig.-1]

3
2. STRUCTURE
2. 1 Expanded View and Part List
17
16
15
14
13

1 2

Disk stopper
Gland
12
5
20
21
Neck 7

8
11
Flange surface
10
[Fig.-2] 22 [Fig.-3]
Bottom

<Table-2> 304YA Parts List

No. Description Q'ty Remarks No. Description Q'ty Remarks
1 Body 1 14 Gland packing 1 set 
2 Disc 1 15 Rough gland 1 set
3 Shaft 1 16 Gland flange 1
5 Seatring 1  17 Hexagon bolt 2
7 Seatring retainer 1 2 *1
20 Ball 
8 Shaft bearing 3 3 *2
10 Bottom cover 1 2 *1
21 Hexagon socket set screw 
11 Bottom gasket 1  3 *2
12 Taper pin 2 22 Hexagon bolt 4
13 Packing retainer 1 22 Spring washer 4
*1 For nominal sizes of 40 mm to 100 mm, *2 For nominal sizes of 125 mm to 300 mm
Remarks: The ★ indicates recommended spare parts. They are supplied as “Seatring set” with a small hexagonal spanner to
remove hexagon socket set screw (P.No.21).
4
3. PRECAUTIONS FOR USE
3. 1 Safety Measures
3.1.1 Handling of this product
1) This product should be assembled, operated, maintained, etc. by personnel who have read
WARNING
this document thoroughly and understood the contents well.
2) The work should be performed while wearing protective gear, such as a helmet, safety belt,
protective glasses, working gloves and safety shoes, in accordance with laws and regulations,
and safety provisions of business establishments.
3) Do not stand or place heavy objects on this product, as this may cause the product to be dam-
aged, resulting in falling accidents.

3. 1. 2 Safety check
Equipment should only be dismantled after the following points have been checked to ensure safety.
WARNING
1) Safety precautions for this product, such as prevention against falling of parts, material or
other accidental happenings, have been taken.
2) The surface temperatures of the product, flanges, and pipes are at a level where the surfaces
can be touched.
3) The pressure in the piping is the atmospheric pressure, and fluid has been drained out from
the inside of the piping.
4) When the fluid flowing through the piping is toxic, flammable or corrosive, adequate safety
measures have been taken.
5) Energy sources of the related facilities, such as power supplies and air sources, have been
shut off.
6) No fluid harmful to the human body is adhered on this product or peripheral piping.
Before restarting of the unit, check the following items.
1) The product and the actuator are secured firmly.
2) There is no failure or damage to the appearance, or loss of parts.
3) Tools have not been left on the product or pipes.
4) Nothing hinders operation of the product (operation of the lever and handle, opening/closing of
the valve).
5) Safe evacuation procedure is already introduced in case of unexpected movements, leakage,
etc.

3. 1. 3 Water hammer and steam hammer

1) Should be check whether there is water hammer and steam hammer during operation.
WARNING
If water hammer or steam hammer occurs, this product and peripheral piping materials may
be damaged.
2) For a lever type, do not open or close the valve abruptly because it causes water hammer.
3) For a pneumatic cylinder valve with a speed controller, the speed controller is fully opened
when shipped. If the opening/closing time is short, water hammer or steam hammer may oc-
cur, resulting in damage of the product. Therefore, be sure to adjust the opening/closing time.
4) Note that piping conditions may cause water hammer or steam hammer which has an influ-
ence on the product by stopping pump operation, opening/closing operations of other valves.

3. 1. 4 Cavitation
Design should be performed to prevent cavitation.
WARNING This product can be operated at the intermediate valve opening (Opening: 30° or more). However, if
abnormal noise or vibrations are generated by the product or peripheral piping, cavitation may have
occurred.
When this product is used for long periods of time in this state, the product or piping materials may
be damaged. Therefore, prevent cavitation by changing the valve opening, pressure, flow rate, etc.

5
3. 2 Transportation and Storage
3. 2. 1 Transportation and Transfer
1) Products with large mass (approx. 20 kg or more) should be transported using equipment or a
WARNING machine, not by manpower alone. See the catalog, product drawings, etc. issued by our com-
pany for details on the mass of this product.
2) Qualified personnel should perform work with a forklift or a crane, or slinging work in accor-
dance with laws and regulations, and safety provisions of business establishments. In addition,
observe section 「3. 2. 2
3) Protect this product sufficiently before transportation so that it is not damaged. Damage
causes leakage or corrosion.
4) Use containers for ocean transportation. If containers are not used, this product becomes de-
teriorated due to salty sea breeze.
5) Use a covered vehicle for inland transportation to avoid exposure to wind and rain.
If an uncovered vehicle is used, cover the product with a protective tarp.
6) Do not throw the product and do not apply a heavy load.
3. 2. 2 Drop and falling
1) At lifting up and slinging work, perform the work while paying thorough attention to safety.
WARNING E.g., check the mass well in advance, and use a lifting tool or equipment corresponding to the
mass, but do not stand under a hung load.
2) Transportation shall be performed under sufficient illumination to secure safety of scaffolding.
Avoid work on unstable pipes, etc.
3) At unloading or transportation between warehouses, this product should be held properly to
prevent it from falling and being damaged.
4) Do not suspend or hoist this product by hanging a hook on the handle. Otherwise, the product
may be damaged or fall, which is very dangerous. Suspend the product by tying down a well-
balanced position, such as the neck section of the valve body, with material that does not dam-
age the product, such as nylon sling.
3. 2. 3 Packing state
This product is shipped in the full-close position, except for the single-acting type air-to-close pneu-
CAUTION matic cylinder. Be careful not to damage the edge of the disc, Seatring, and flanges.
3. 2. 4 Unpacking
1) Unpack this product immediately before installing it to the piping. Do not leave the product
unpacked for long periods of time to prevent adherence of dust and harmful substances and
deterioration due to ozone or ultraviolet rays. Otherwise, degradation in performance, contami-
nation, discoloration or material deterioration may occur.
2) Be careful not to damage this product with a cutter, etc. when unpacking.
3. 2. 5 Storage
Store this product as follows to prevent degradation in performance, contamination, discoloration,
and material deterioration.
1) Store this product in a place with no dust or water droplets while avoiding direct sunlight, high
temperatures and humidity.
2) Store this product indoors (ambient temperature: 0°C - 50°C, humidity: 70% or less) without
removing the cardboard packaging or the protective material attached to the valve body.
3) For cardboard packaging, high humidity may reduce the strength of the box and the packaging
may be broken, which may result in damage of the product. Be adequately careful not to get
the packaging wet.
4) Do not store this product in an atmosphere that contains corrosive gas. Otherwise, the parts
may be subject to corrosion, resulting in an impairment of functions.
5) Do not drop, overturn or vibrate this product, and do not apply a heavy load to the product dur-
ing storage. Otherwise, functions may be impaired.
6) Do not stack this product at storage. A load collapse may occur, which causes damage to per-
sonnel and/or the product. (Refer to section 3. 2. 2.)
7) Store this product in the full-close position. Open and close the prod-
uct about once every three months.
8) Store this product while no load is applied to the actuator. Oth-
erwise, the handle shaft, etc. may be deformed.
9) For long-term storage, apply Ferro-Guard (Ferro-Guard
#1009, US Ronco Laboratories, INC.) once a year to the
plated parts (indicator, bolts, nuts, handle shaft, etc.). [Fig.-4]
6
 3. 3 Installation and Working Environment
3. 3. 1 Installation location and working environment
For installation locations, necessary work space should be provided for expected work and mainte-
WARNING nance, such as operation of the actuator, wiring and piping.
In the following installation locations or working environments, special actions, such as compliance
with laws and regulations, may be required in some cases as well as functional conformance to
specifications. If there are any questions, please contact our sales department at the planning stage.
1) Special working environments which are not specified in the specifications
2) In the case where substantial damage to human beings, assets, environments, etc. is predict-
ed if this product fails
E.g.: Facilities related to the High Pressure Gas Safety Act, facilities related to the Industrial
Safety and Health Act, Nuclear power related facilities, medical facilities, vehicles, etc.

3. 3. 2 Atmosphere of installation location

The following measures should be taken depending on the atmosphere of the installation location.
CAUTION
1) Locations which are exposed to gas containing salt, corrosive gas, chemical solution, organic
solvent, steam, salt water, etc. should be avoided.
2) If there is a possibility that this product is exposed to direct radiant heat or chemicals, the
product and attachments should be protected with covers.
3) Do not submerge this product. When it is installed in a place that is usually exposed to water,
such as near a cooling tower, protect the product and attachments with covers.
4) When this product is installed in a salt damage zone, take measures against salt damage.

3. 3. 3 Temperature of installation location and working environment

Using this product out of the allowable working temperature range causes thermal degradation or
hardening of Seatring and O-rings, faulty operation due to thermal expansion of parts or difference
of thermal shrinkage, etc.
1) The ambient temperature of the installation location should be within the ambient temperature
range of the specification (section 「1. 2).
2) When this product is exposed to direct sunlight, maintain the working temperatures of the
product and the actuator under the upper limit.
3) This product should be kept away from heat sources, and should be installed in a location
whose temperature is within the specified ambient temperature range. Not that temperature
near a motor, an engine, an air compressor, a boiler, etc. may exceed the specified ambient
temperature range.
4) When this product is used in an environment where the temperature of the internal fluid
changes significantly, note that leakage tends to occur due to difference in the coefficients of
thermal expansion of materials.

3. 3. 4 Vibration and impact at installation location

The following measures should be taken if there are vibrations or impact at the installation location.
CAUTION
1) When this product is used in the following conditions, check vibration or impact conditions,
such as acceleration values, and contact our sales department.
① Location where excessive vibration or impact of more than 9.8 m/s2 is expected to be ex-
erted
② Location where vibration or impact is exerted continuously
2) Installation sections and connecting sections, etc. should be locked to secure and fasten them
firmly.
3) Vibration isolation measures should be taken to reduce vibrations or impact on the machine.
Piping should be secured with supports, or vibration isolation material should be installed.
4) Joints should be checked periodically against looseness and deformation. In case of abnormal
conditions, bolts should be retightened or parts should be replaced. Coming off of the bolts
may cause falling off or rotation in an unexpected direction of this product.
5) For a gear type, the handle may rotate due to vibrations. Take measures to secure the handle, such
as handle lock, when necessary. Handle lock can be provided as optional at time of order.

7
3. 3 Installation and Working Environment (Continued)
3. 3. 5 Removal and replacement of this product and the actuator
1) The seat sealing performance of this product depends on the full-close adjustment mechanism
of the actuator. Therefore, make alignment marks before removing the actuator, and take care
that its position is not changed at reassembly.
2) Do not remove the actuator and replace it with other actuators or modify the actuator. When
the actuator is replaced or modified, the warranty is no longer applicable.

3. 3. 6 Precautions for installation of thermal insulating material for the valve

If a thermal insulation thickness is 50 mm or less from the pipe outer diameter and the flange outer
CAUTION
diameter, the gland can be retightened. Leakage of fluid from this product to the outside may hap-
pen due to reduction in the tightening force as a result of stress relaxation of the packing during
commissioning and operation. In consideration of leakage, install the thermal insulation so that the
lever and the handle can be operated unhindered.
In addition, install the thermal insulation so that the indication of opening can be seen. For a gear
actuator, there is an option to extend the indication of opening. Please contact our sales.

Thermal
insulation Thermal
50 insulation

50

50

Outside diameter of Valve body

the flange

[Fig.-5]
3. 3. 7 Condensation
Condensation may occur in the actuator when the temperature of the actuator is different from the
CAUTION ambient temperature.
There is an option to prevent condensation of the actuator. Please contact our sales.

3. 3. 8 Precautions for selection

1) This product has a structure where the body gets wet in contact with the fluid. Pay attention to
CAUTION corrosion of the body due to the fluid used. Especially, Be careful to FCD450.
2) A pressure direction (flow direction) is specified on the body. Use with pressurization in the op-
posite direction is not guaranteed.
3) The pressure test is performed with water at the factory. When the fluid is gas/vapor and a little
external leakage is a problem, please contact our sales department.
4) This product use RPTFE for seat ring, so it is very weak for rust or jam and easy to get injured.
If get injured, happen leak at during an early stage.
5) If used fluid be powder or slurry, it is piled up on stopper or seal surface for disc. And lifetime
for product might be shorter.

8
 3. 4 Installation Precautions
3. 4. 1 Precautions before installation
1) The working pressure, fluid and temperature ranges of this prod-
uct depend on the materials of the Seatring and the disc. Prior to
installation to the piping, be sure to check the valve specifications
Specification
with nameplates, catalog, drawings, etc. (Materials are described at name plate
the arrow position in [Fig.-6].)
2) Secure scaffolding and illumination required for operation and work
at the installation location.
3) Provide supports to pipes as required so that excessive load is not
applied to the pipes due to weight or operation of this product. [Fig.-6]
4) Use standard flat-face or raised-face flanges specified in the product specifications (section 1. 2).
5) This product cannot be connected to a lining pipe. Connect the product to a carbon steel pipe
for piping, carbon steel pipe for pressure piping, or stainless steel pipe for piping whose inner
diameter is equal to or bigger than the “minimum pipe inner diameter” shown in the table in
section 6. 1.

3. 4. 2 Precautions at time of installation

When connecting this product to the piping, pay attention to the following points.
If dents or scratches are made on impact, to ensure safety stop use of the product and replace it.
1) Prior to installation to the piping, sufficiently clean piping members to remove shavings, cutting
oil, waste material, etc. from the inside.
2) This product and pipes should not be subjected to extreme force, being hit, or impacted. If the
product is deformed or damaged due to rough handling, leakage or faulty operation may occur.
3) A pressure direction (flow direction) is specified for this product. When installing, make the
pressure direction match the direction indicated by the arrow on the valve body. Pay attention
to the following installation conditions.
① Piping with the actuator facing downward is not allowed.
② If your application involves pressure being applied in both directions, please contact our sales.
③ Be careful of the shaft direction when piping conditions are as shown in [Fig.-7].

〈Incorrect Installation〉 〈Correct Installation〉 〈Incorrect Installation〉 〈Correct Installation〉

Centrifugal Pump
(Horizontal Shaft) Pump Shaft
(Horizontal)
Valve Shaft 5D or longer
Valve Shaft
Flow Flow
Flow Flow

Valve Shaft (Horizontal)

Valve Shaft (Vertical)
5D or longer
Valve Shaft Valve Shaft
Centrifugal Pump (Horizontal Shaft) Pump Shaft Valve Shaft
Pump Shaft (Vertical) (Vertical) (Horizontal) Flow Flow

Flow Flow

Valve Shaft Valve Shaft 5D or longer

Pump Discharge Pump Discharge Valve Shaft
(Vertical)
Flow Flow
Pump Shaft
Axial Pump (Vertical Shaft) (Vertical) Valve Shaft
Pump Shaft (Vertical) (Vertical)

Flow Flow

〈Incorrect Installation〉 〈Correct Installation〉

Valve Shaft
(Horizontal)
5D or longer
Pump Discharge Pump Discharge
Flow Flow

Valve Shaft Valve Shaft

Valve Shaft
All the Valve Shafts The orientation of the
have the same orientation. Valve Shafts is alternating.

[Fig.-7]

9
3. 4 Installation Precautions (Continued)
4) When installing, do not stand on this product or insert the product by hitting it.
5) Be sure to use gaskets between the pipe flanges and valve. Joint sheet gaskets*1, spiral gas-
kets*2, and PTFE Envelope gaskets can be used. Do not use soft gaskets such as ones made
of rubber. Otherwise, external leakage occurs. For piping gasket sizes, refer to the table in sec-
tion 6. 3.
*1 When the joint sheet gaskets are used, select products whose size is in compliance with
former JIS B 2404-1999 for 65 mm. For the sizes other than 65 mm, JIS standard products
can be used.
*2 For the spiral gaskets, use our special products.
6) For this product, fluid is sealed by the Seatring compressed with the force as a result of the
pipe flange compressing the gasket. When connecting the product to the piping, align the
center of the product with the center of the flange to press the Seatring accurately. The align-
ment for piping work becomes easy by using the alignment rib of this product. If this product
is operated while the centers are not aligned, breakage, faulty operation, external leakage, or
seat leakage may occur.
7) When tightening piping bolts, pay attention to the following precaution. For tightening proce-
dures, refer to section 4. 1. 1.

Using an impact wrench

Please be careful when using a high-torque impact wrench for piping installation or retighten-
CAUTION
ing piping bolts of butterfly valves. Unless an appropriate impact wrench is used and work with
it is performed properly, deformation or damage of the valve body, Seatring, pipe flanges, pip-
ing bolts, etc. may happen. If you use an impact wrench, use one whose maximum torque is no
more than the “Max. allowable value” in the following table.
<Table-3> Maximum Allowable Torque for Metal Flanges (Unit: Nm)
Bolt Nominal Size M12 M16 M20 M22 M24 M30 M36
64 150 300 400 640 1280 2200
Max. allowable value
or less or less or less or less or less or less or less
Note) Lubricant should be applied to bolts properly

8) Never weld when this product is in the piping. Installation of

the product immediately after welding the pipe flange will
lead to heat damage to the Seatring, resulting in adverse
consequences. Make sure that the temperature is low and
weld spatters have been removed before installing the
valve.

[Fig.-8]
9) Damage of the Seatring or flange leakage may occur if the flange face that contacts the seat
ring of this product is as shown in [Fig.-9].

● Excessive weld penetra- ● Sharp edge ● Rough surface finishing

tion, chamfering Sharp angles and burrs may Protrusions or indentations
The resulting oversized inner damage the flange surface. on the sealing surface may
pipe diameter may cause cause flange leakage. flange
flange leakage. leakage.
[Fig.-9]

10
 3. 4 Installation Precautions (Continued)
10) Align the primary side pipe with the secondary side pipe properly and make sure that the
pipes are parallel and there is no distortion. If the alignment is not proper, external leakage,
seat leakage, or faulty operation may occur.

Poor centering alignment Poor parallel Distortion

of the pipes alignment [Fig.-10]
11) When installing a non-return valve, pump, or flexible joint with this product, insert a short pipe
between the part and the product. Not inserting a short pipe may cause the disc to make con-
tact with the other device during operation, resulting in faulty operation, external leakage, and
seat leakage. Refer to section 6. 1 for protruding dimensions of the disc.
12) Connect this product to the primary side of a bent pipe (elbow, tee). If the product is connected
to the secondary side by necessity, secure a straight pipe distance of 5 times or more of the
pipe diameter from the bent pipe. In addition, the product should be positioned so that the flow
velocities at the right and left sides of the shaft are the same. [Fig.-7]
If the product is closely connected to the secondary side of a bent pipe, etc., flow velocity and
pressure distribution cause unbalanced torque on the disc, which may increase the operating
force or have an adverse effect on the performance and service life of the product.
13) When this product is connected to the secondary side of a control valve, pump outlet, or re-
ducer, secure a straight pipe distance of 5 times or more of the pipe diameter. In addition, the
valve should be positioned so that the flow velocities at the right and left sides of the shaft are
the same. [Fig.-7]
14) When replacing a valve with a long face-to-face dimension (e.g. gate valve, globe valve, ball
valve) with this product, you must insert a short pipe and adjust the total length of the short
pipe and the face-to-face dimension of this product to the face-to-face dimension of the origi-
nal valve flange. Use the equation below when making a short pipe. [Fig.-11]

Existing valve

t L1 t
<Table-4>
Length of short pipe
L2 = L1 – L - t mm
L2 : Length of short pipe mm Piping gasket Piping gasket
L1 : Face-to-face dimension of mm
Butterfly valve
existing valve
L : Face-to-face dimension of mm Pipe Short pipe Pipe
TOMOE butterfly valve
t : Thickness of gasket packing mm

L2 L
t
t L1 t
[Fig.-11]
15) After piping work is completed, set this product to the full-open positon and check that the disc does
not make contact with the inner surface of the flange.
16) Also, insulate around the valve body when the valve will be used with high-temperature fluids that
exceed 60°C.
11
3. 5 Precautions for Safe Handling After Installation
3. 5. 1 Precautions for safe handling after installation
After this product is connected to the piping, perform Check for
checks while paying attention to the following points. If the any leak
checks are not performed, serious accidents may occur,
such as damage of the product.
1) Prior to operating, clean pipes and remove foreign
material from the inside and outside of the pipes.
2) Prior to operating, increase the internal pressure of
the piping and check for leakage from the flanges,
glands, and bottom. Make sure that the internal
pressure does not exceed the rated pressure of the
valve at the leakage check. [Fig.-12]
3) If leakage from the flanges is observed, reduce the pressure and then retighten the piping
bolts and nuts.
CAUTION Refer to “Piping bolt tightening procedures” in section 4. 1. 1 10) for the tightening proce-
dures. If leakage from the bottom is observed, check for looseness of the hexagon bolts at the
bottom. If leakage from the glands is observed, retighten the hexagon bolts of the glands. If
leakage does not stop, release the piping internal pressure and remove this product from the
piping. Then replace the glands or spare parts at the bottom.
4) When performing a pressure test of the piping including this product, the pressure should be
the rated pressure of this product × 1.5 times or less.
When performing a pressure test of the piping where the pressure exceeds the rated pressure,
set the product to the full-open positon.
5) After installation, open and close the product about once every two weeks if the product is not
used for long periods of time.
6) Do not use this product as a blank flange by setting the product to the full-close position.

3. 5. 2 Precautions for operating this product

1) Never loosen the bolts, pins or piping bolts of this product when the inside of the piping is un-
WARNING der pressure. Otherwise fluid jets to the outside, which is dangerous.
2) Do not remove the actuator from this product when the inside of the piping is under pressure.
Unexpected abrupt valve operation may occur or the shaft may spring out.
WARNING 3) When this product is used at the intermediate opening, the opening should be 30° or more. If
the product is used continuously with the opening of 30° or less, damage of sheets, or dam-
age, vibration and noise of the piping may occur due to jet speed increase or cavitation. (Refer
CAUTION
to section 3. 1. 4.)
4) Do not loosen the stopper bolts of the actuator and the Indicator
indicator installation bolts of the lever. Otherwise, seat
leakage may occur because the full-close position is
shifted. When the stopper bolts are moved, perform
full-close position adjustment again in accordance with
“Valve Body Full-Close Position Adjustment Proce-
dure” in section 5. 5. Stopper bolt
5) For a manual gear type actuator, the stopper works
when the indicator shows full-open or full-close. Do not Hexagon nut
[Fig.-13]
apply excessive force to the handle wheel from this
state. Otherwise, the gear box will be damaged.
This product has been adjusted so that the maximum sealing performance can be obtained
at the full-close position adjusted with the stopper bolts. The sealing performance will be dete-
riorated and torque becomes low at a position which is deeper or shallower than the adjusted
position. Therefore, it is not necessary to rotate the handle forcibly.
6) Opening and closing operation of the lever and the handle wheel must be done by hand. When
operating the handle using an ancillary tool, such as a Wilky key, this may cause damage or
failure of the product.
7) After installation and before operation, be sure to open and close the product once or twice.
8) After trial operation or operation over a fixed period, retighten the piping bolts and nuts. Par-
ticularly, in applications involving high-temperature fluids, the tightening force of the bolts may
CAUTION be reduced due to stress relaxation of the piping gaskets, which may cause flange leakage.
12
 3. 6 Maintenance
3. 6. 1 Daily Inspection
Perform daily inspection on the following.
<Table-5> Daily Inspection Procedure
Inspection Inspection
Inspection Points Countermeasure
Description Procedure
Retighten the piping bolts and nuts.
Pipe joints Visual check Align the valve center with the pipe center and
retighten the piping bolts.
Fluid external
Disassembly and maintenance (Spare parts
leakage
Bottom, valve surface Visual check replacement*1)
Valve replacement
Gland area Visual check Retighten the bolts.
Change the valve opening. Review the flow
Appearance of the valve rate and pressure.
Abnormal noise, and actuator Listening, Retighten the bolts and nuts. Remove the
vibration Piping around the valve Check by touch sources of vibrations.
Bolts and nuts Disassembly and maintenance (Check for
damage of the parts.)
Retighten the bolts and nuts.
Looseness of the Visual check,
Bolts and nuts Retighten the pressure part after reducing
bolts and nuts Check by touch
pressure.
Check that the opening and closing positions
Presence or absence of are correct with the indicator.
leakage from the second- Listening, Remove foreign material by flushing water with
Seat leakage ary side Visual check, the valve fully open (section 3. 6. 6).
(Flow meter, pressure Measurement Remove the valve from the piping (section 3. 6.
gauge, drain) 7) and perform check and cleaning.
Replace *1 pare parts
Check of opening and
Visual check,
Valve operation closing positions Check that the opening and closing positions
Operational
check Manual valve: Operability are correct with the indicator.
feeling
Automatic valve: Operation
Valve damage If any damage is observed, stop use of the
Valve surface Visual check
check valve and replace it.
*1 Replace the spare parts around after 3000 times of opening and closing (Open - Close - Open: 1 time) or
one year operation at room temperature using fresh water. The replacement timing may become faster de-
pending on the working environment. Please replace the spare parts (refer to the Expanded View in section
2.1) based on the number and term.

3. 6. 2 Periodic inspection
Perform periodic inspection on the following items once every 6 months.
<Table-6> Periodic Inspection Procedure
Inspection
Inspection Points Inspection Procedure Countermeasure
Description
Corrosion and Remove the valve
damage of the Disc from the piping and Valve replacement
disc perform visual check.
Abrasion and Remove the Seatring Clean the disc and Seatring (section 3. 6. 3).
damage of the Seatring from the piping and Replace *1 pare parts
Seatring perform visual check. Valve replacement.
Valve operating Opening/Closing
Valve, actuator Actuator replacement, valve replacement
condition operation
*1 Replace the spare parts around after 3000 times of opening and closing (Open - Close - Open: 1 time) or
one year operation at room temperature using fresh water. The replacement timing may become faster de-
pending on the working environment. Please replace the spare parts (refer to the Expanded View in section
2. 1) based on the number and term.

3. 6. 3 Cleaning of the disc and disc stopper

For pneumatic cylinders and motors, before putting your hand in the valve, take precautions, such as shut-
ting off air sources and turning off the power, to prevent the actuation. It is very dangerous if your hand is
caught by the suddenly closing the disc. Particularly, for single-acting cylinder, it is necessary not only to
shut off power supplies but also to check that the operation pneumatic pressure has been released.
1) When removing this product from the piping and cleaning it for periodic inspection, etc., clean
the Seatring using a clean waste cloth/sponge, etc. and a neutral detergent or alcohol, while
avoiding scratches on the Seatring.
2) Clean the edge of the disc with a waste cloth.
3) Check for scratches and wear on the Seatring inner surface and the edge of the disc.
4) Check that no foreign material adheres to the disc stopper.

13
3. 6 Maintenance (Continued)
3. 6. 4 Replacement of spare parts
This product should be disassembled and assembled in a clean location which is free from dirt,
waste material and dust.
Refer to section 2. 1 “Expanded View and Part List” and “MAINTENANCE” in Chapter 5 for type
and replacement procedures of spare parts.

3. 6. 5 Rust prevention procedure

Be sure to use the rust preventive agent specified blow.
<Table-7> Rust Prevention Procedure
To be applied to: Rust preventive agent Product Name (Manufacturer)
Plated parts Ferro-Guard #1009
Rust preventive agent
Indicator, bolts, nuts and handle shaft (US Ronco Laboratories, INC.)

3. 6. 6 Countermeasures to address abnormalities

1) The work should be performed while wearing protective gear, such as a helmet, safety belt,
WARNING protective glasses, working gloves and safety shoes, in accordance with laws and regulations,
and safety provisions of business establishments.
2) When the fluid which flows through the piping is toxic, flammable or corrosive, adequate safety
measures should be taken.
3) Before retightening the pipe flanges, be sure to reduce the pressure in the piping to the atmo-
spheric pressure.
4) In case of abnormal operation, possible causes are clogging of foreign material, damage of
the Seatring, etc. If you continue to use the valve, serious accidents may occur due to dam-
age. Perform checks in accordance with the following procedures.
① To remove foreign material, keep the disc in the full-open positon and flush fluid to remove
foreign material.
② If normal operation is still not restored through the above procedure, damage of the seat
ring is possible.
Remove the Seatring from the piping and check the Seatring.

3. 6. 7 Removal/Installation from/to the piping

1) Before removing this product from the piping, release the residual pressure and remove fluid
WARNING from the equipment and the piping completely. Otherwise, jetting of fluid to the outside and
unexpected movements may occur.
2) Take necessary measures so that fluid does not flow into applicable pipes accidentally during
the work.
3) When this product is removed, fluid may leak from the inside. Provide protection as required.
4) Remove/install this product from/to the piping with the product in the full-close position so that
the disc does not protrude from the face. (Refer to section 4. 1. 1 for detailed procedures.)
5) Remove all the bolts and nuts except those on the lower side. Remove the valve. At this time,
use of jack bolts in between the flanges will assist in removing the valve more easily.

3. 6. 8 Disposal
1) Do not dispose of this product by incineration. There is a possibility of generation of toxic gas
from synthetic rubber or nylon resin parts and bursting. Therefore please dispose of this prod-
uct as general industrial waste. The product does not contain materials which cannot be dis-
posed of as general industrial waste.
2) For segregated disposal, classify the parts in accordance with materials specified on drawings.
3) This product should be disposed of in accordance with laws and regulations, local government
ordinances, standards of business establishments, etc.

14
4 INSTALLATION
4. 1 Installation Procedure
4. 1. 1 Installation procedure
At installation, read “Installation Precautions” in sec-
tion 3. 4 thoroughly and then perform installation in
accordance with the following procedures.
[Fig.-14]
CAUTION

When installing a non-return valve, pump, or flexible

joint made of rubber with this product, insert a short
Close pipe between the part and this product. Otherwise,
the disc may make contact with the other device
during operation, resulting in faulty operation and
leakage.

[Fig.-15] 1) Clean the flange face that will make contact with
this product. If there is rust or some other foreign
material sticking to the flange face, remove it and
clean the flange face with a suitable cleaning fluid
(alcohol, neutral detergent, etc.). [Fig.-14]
Remove foreign material from the piping completely
before connecting this product to the piping.
2) Before installation or removal work, set the valve
disc in the full-close position. [Fig.-15]
3) After aligning both flanges, insert the piping bolts
as shown in the figure and secure the product to
[Fig.-16] prevent it from dropping. [Fig.-16]
4) Insert jack bolts in the position shown in the figure
to widen the distance between the flanges. Push
the flanges and make the distance between the
flanges 6 to 10 mm longer than the valve face-to-
Jack bolt face dimension. Do not remove the jack bolts until
all the piping bolts are installed. [Fig.-17][Fig.-18]
5) Do not suspend this product by hanging a hook,
etc. on the handle. Suspend the product by tying
down a well-balanced position, such as the neck
section of the product, with material that does not
damage the body, such as a nylon sling.[Fig.-18]
Face-to-face dimension [Fig.-17] 6) A pressure direction (flow direction) is specified for
+ 6 ～ 10mm
this product. When installing, make the pressure
direction of the valve match the direction indicated
by the arrow on the valve body. Insert the product
while taking care not to damage the valve flange
face. At installation, if the product is pushed in the
Flow direction indicator flange forcibly, the flange face will be damaged,
which will cause leakage.
Neck
Be sure to widen the distance between the flanges
using jack bolts, etc. before inserting the product.
[Fig.-18]
Piping gasket
7) Insert piping gaskets between the end faces of the
Piping gasket valve and the pipe flange faces.

Jack bolt [Fig.-18]

15
4. 1 Installation Procedure (Continued)
8) When this product is inserted completely, insert
the piping bolts to support the alignment rib.
9) After all the piping bolts are installed, remove the
jack bolts.
10) Align the flanges with the product accurately. Tight-
en the piping bolts with the following procedures so
as not to tighten the bolts on one side too much or
too little. For this product, fluid is sealed by the seat
ring compressed with the force as a result of the
Alignment ribs pipe flange compressing the gasket. When con-
necting the product to the piping, align the center
of this product with the center of the flange to press
Jack bolt the Seatring accurately. The alignment for piping
[Fig.-19] work becomes easy by using the alignment rib. If
this product is operated while the centers are not
aligned, breakage, faulty operation, external leak-
age or seat leakage may occur.
※ When you use an impact wrench, be sure to
read “section 3. 4. 2”.
CAUTION

Piping bolt tightening procedures

When there is no appropriate tightening procedure in business establishments or ⑧ ①
internal standards, tighten the bolts and nuts with the following procedures.
1) Clean the bolts and nuts and apply lubricant to them.
(Do not use rusty or damaged bolts and nuts.) ④ ⑤
2) Tighten the bolts and nuts by hand in any desired order.
3) Tighten the bolts and nuts in any desired order with approx. 20% of the speci-
fied tightening torque.
4) Tighten the bolts and nuts, alternate diagonally (refer to the right figure) with ⑥ ③
approx. 70% of the specified tightening torque.
5) Tighten the bolts and nuts, alternate diagonally, with approx. 100% of the
② ⑦
specified tightening torque.
Example) Bolt tightening sequence
6) Tighten the bolts and nuts, alternate diagonally, with approx. 100% of the
specified tightening torque again. [Fig.-20]
7) Tighten the bolts and nuts clockwise with approx. 100% of the specified tight-
ening torque.
For this product, bolts that are tightened once may become loose due to stress relaxation of the piping gaskets.
Be sure to perform retightening in 6) and 7) repeatedly until the bolts and nuts are tightened evenly.

Flange of both ends

11) For accurate alignment between the flanges and
this product, tighten the flanges at both ends tem-
porarily and tighten this product finally first. [Fig.-21]
12) After installation, open and close the product to
verify that the operations from/to full-open to/from
full-close are smooth.

[Fig.-21]
Flange of both ends

16
5 MAINTENANCE
5. 1. Seatring Disassembly/Assembly Procedures
5. 1. 1 Seatring disassembly procedure
For periodic inspection or in case of trouble due to
damage and wear of the Seatring, etc., carry out the
following procedures while referring to the expanded
view.
1) Secure the metal section of the body ① using a
vice so that the flanges are not damaged. Open the
① Body disc ② approx. 30°. [Fig.-22]
② Disc
2) Remove the Hex. socket set screws  on the front
⑦ Seatring 　　 of the Seatring retainer ⑦ . [Fig.-22]
retainer
3) Carefully grasp the inner side of the Seatring re-
tainer ⑦ and pull it out toward you by hand. The
ball ⑳ inserted on the outer side of the retainer
may pop out during removal, so care must be taken
⑤ Seatring not to lose it. [Fig.-22]
4) Remove the Seatring ⑤ from the seat ring retainer
⑦ . [Fig.-22]
⑳ Ball 5) Thoroughly clean the Seatring mounting faces of
 Hex. socket set screw the body ① and the Seatring retainer ⑦ , and the
disc ② using a suitable cleaning fluid, such as
[Fig.-22] alcohol or a neutral detergent. [Fig.-23]

5. 1. 2 Seatring assembly procedure

1) Set the disc ② to the full-close position. [Fig.-24]
2) Install a new Seatring ⑤ to the Seatring retainer
⑦ . Set the ball ⑳ on the periphery of the Seatring
retainer ⑦ and install it on the body ① . [Fig.-24]
3) Screw the set screws  into the tap hole provided
on the front face of the Seatring retainer ⑦ . Make
sure that the Hex. socket set screws  is com-
pletely screwed in so that it does not protrude from
the front face of the Seatring retainer ⑦ . [Fig.-25]
[Fig.-23]

⑳ Ball

 Hex. socket
set screw

[Fig.-25]
② Disc
4) Open and close the valve to ensure that the seat
 Hex. socket set screw ring retainer ⑦ is properly secured to the body.
⑳ Ball

⑤ Seatring

⑦ Seatring retainer
[Fig.-24]
17
5. 2 Removal of Valve Body and Actuator
L26 Hex. socket set screw WARNING
L27 Hexagon nut
Before installing/removing the actuator while this
Lever product is installed to the piping, check that the
pressure in the piping is atmospheric pressure and
the fluid is drained out from the inside.

L21 Notch plate

5. 2. 1 Lever type
1) Secure the metal section of the body ① using a
Screws  Bonnet vice so that the flanges are not damaged. Set the
valve opening to the full-open position. [Fig.-26]
③ Shaft 2) Make alignment marks on the body ① and indica-
tor L21 .
① Body
3) Remove the Hex. socket set screw L26 and hexagon
nut L27 that secure the shaft ③ and lever.
4) Remove the hexagon nuts and spring washers (2
pairs) that secure the body ① and indicator L21 .
5) Lift the lever upward and remove it.
6) Be careful not to lose the removed parts.

[Fig.-26]

5. 2. 2 Worm gear
Actuator
1) Secure the metal section of the body ① using a
vice so that the flanges are not damaged. Set the
valve opening to the full-open position. [Fig.-27]
2) Make alignment marks on the connecting part be-
tween this product and the actuator.
 Heat insulation sheet 3) Remove the hexagon bolts and spring washers (4
pairs) that secure the body ① and actuator.
 Bonnet 4) Lift the actuator upward and remove it.
5) Be careful not to lose the removed parts.
③ Shaft
Screws

① Body

② Disc

[Fig.-27]

18
 5. 3 Disassembly/Assembly Procedures of Gland area
5. 3. 1 Disassembly procedure of Gland area
⑯ Gland flange 1) Set the disc ② to the full-close position.
⑮ Rough gland 2) Remove the hexagon bolts ⑰ and then remove the
⑭ Gland packing gland flange ⑯ .
⑬ Packing retainer 3) Pull out the rough gland ⑮ from the body ① .
4) Remove the gland packing ⑭ from the body ① us-
ing a packing tool or a scriber or similar tool. If the
packing retainer ⑬ can be removed, remove it as
① Body
well.

5. 3. 2 Assembly procedure of Gland area

1) Clean the gland packing hole on the body ① to
remove waste material and other foreign material.
2) Clean the parts before assembly.
3) When the packing retainer ⑬ was removed, install
[Fig.-28] it in the gland packing hole of the body ① .
4) Insert the gland packing ⑭ into the gland packing
hole on the body ① and attach the rough gland ⑮
onto it. When inserting the gland packing ⑭ , insert
the male adaptor (c), V rings (3 pcs)(b), and the
female adaptor (a) in that order, one by one, in the
direction shown in [Fig.-29].
a 5) Attach the gland flange ⑯ and tighten the hexagon
bolts ⑰ equally on the left and right.
6) Set the disc ② to the full-close position.
a 7) After installing the actuator, open and close the
b b valve to verify that the operations are smooth.
c

⑭ Gland packing

[Fig.-29]

19
5. 4 Assembly Procedure of Valve Body and Actuator
L26 Hex. socket set screw CAUTION
L27 Hexagon nut
・ When installing the original actuator to this prod-
Lever
uct without the actuator, check the alignment
marks and serial No. before assembly to ensure
that the actuator is the identical one which was
removed from the product.
L21 Notch plate
・ Improper assembly causes misalignment of the
closing position, which may lead to leakage.

Screws  Bonnet
5. 4. 1 Lever type
③ Shaft
1) Secure the metal section of the body ① using a
① Body vice so that the flanges are not damaged. Set the
valve opening to the full-open position. [Fig.-30]
2) Secure the indicator L21 and bonnet  to the body
① with the hexagon bolts, hexagon nuts and spring
washers (2 pairs).
3) Install the lever to the shaft ③ while aligning the
lever with the full-open position of the indicator L21
[Fig.-30]
and secure the lever with the Hex. socket set screw
L26 and hexagon nut L27 .
4) After assembly, turn the lever to verify that the
opening and closing operations are smooth.
5) Finally, adjust the full-close position in accordance
with “Full-close position adjustment procedure
(1T lever)” in section 5. 5. 2.

5. 4. 2 Worm gear type

Actuator 1) Secure the metal section of the body ① using a
vice so that the flanges are not damaged. Set the
valve opening to the full-open position. [Fig.-31]
2) Set the actuator to the full-open position.
3) Insert the thermal insulating sheet  and bon-
 Heat insulation sheet net  onto the body as shown in the figure, and
then insert the actuator. At this time, check that the
alignment marks of the body ① and actuator are
 Bonnet
aligned.
4) Secure the body ① and actuator by tightening the
③ Shaft hexagon bolts and spring washers (4 pairs).
Screws
5) Finally adjust the full-close position in accordance
① Body with “Full-close position adjustment procedure
(2U gear)” in section 5. 5. 3.

② Disc

[Fig.-31]

20
 5. 5 Valve Body Full-Close Position Adjustment Procedure
5. 5. 1 Full-close position reference Depth gauge or the like
＜ Table-8 ＞ Full-close Position Reference
Disc
Nominal Size Full-close Position Reference
mm inch (* For lever type and worm gear type only)
X
40 1 1/2
X
－ 0.5 ± 0.5
10～20°
50 2 Close
65 2 1/2 A B
80 3
Open
100 4 Rotation direction
X-X
125 5 － 1.0 ± 1.0
150 6 Dimensions are specified for the assembled product.
200 8 Measure the dimensions at two points of A and B. The full-
250 10
－ 1.5 ± 1.5 close position reference = B – A.
300 12 [Fig.-32]

5. 5. 2 Full-close position adjustment procedure (1T lever)

Notch plate 1) Set this product to the full-close positon.
2) Loosen the hexagon nut (C). Move the lever while it
is hooked in the notch to adjust the full-close posi-
tion so that the position meets the full-close posi-
Hexagon nut（C）
tion reference.
3) Tighten the hexagon nut (C) using a spanner at the
adjusted position.
[Fig.-33] 4) Turn the lever to verify that the opening and closing
operations are smooth.
5) If re-adjustment is required, repeat the procedures
from the above 1).
※ The full-close and full-open positions are ad-
justed when shipped.
※ If the full-close position is outside the specifica-
tions, the body may be broken when the product
is opened and closed.

5. 5. 3 Full-close position adjustment procedure (2U gear)

1) Set this product to the full-open positon. Check that
Indicator the indicator of the gear box is “OPEN”.
2) Loosen the right hexagon nut (A) in [Fig.-34].
3) Turn the hexagon stop screw (B) by the required
Hex. socket set screw（B） angle using a hexagonal bar wrench so that the
full-close position meets the full-close position
（A）
Hexagon nut reference. When the hexagon stop screw (B) is
turned clockwise, the full-close position of the valve
becomes shallow.
4) After the adjustment, secure the hexagon stop
screw (B) using a hexagonal bar wrench and tight-
en the hexagon nut (A) using a spanner.
[Fig.-34] 5) Operate the gear and check that the product can
be opened and closed.
6) If re-adjustment is required, repeat the procedures
from the above 1).
※ The full-closed and full-open positions are ad-
justed when shipped.
※ If the full-close position is outside the specifica-
tions, the body may be broken when the product
is opened and closed.
21
6. Piping Data
6. 1 Minimum Inner Pipe Diameter and Disc Protruding Dimension at Full-open Position
＜ Table-9 ＞ Minimum Inner Pipe Diameter and Disc
Protruding Dimension at Full-open Position
Unit: mm
Minimum Disc Protruding
Nominal Size Inner Pipe Dimension at Full-open
Diameter Position
mm inch A B C
40 1 1/2 36 5.4 0.9
50 2 42 0.0 5.9
65 2 1/2 59 5.1 12.1

A
80 3 73 15.0 16.0
100 4 92 21.0 23.2 B C
125 5 117 31.5 32.9
150 6 143 45.8 43.4
200 8 193 67.6 63.6
250 10 240 88.2 80.9
300 12 291 107.2 104.4

Note ) The disc of the butterfly valve is inserted into a pipe at full-open position. When you use a pipe or flange
whose diameter is less than the minimum inner pipe diameter, insert a spacer, etc. between the product and
flange.
For details, please contact our sales department.

6. 2 Applicable Pipes
<Table-10> Applicable Pipes
Nominal Size JIS G3452 JIS G3454 JIS G3459
mm inch SGP Sch20 Sch40 Sch10S Sch20S
40 1 1/2 ○ － ○ ○ ○
50 2 ○ ○ ○ ○ ○
65 2 1/2 ○ ○ ○ ○ ○
80 3 ○ ○ ○ ○ ○
100 4 ○ ○ ○ ○ ○
125 5 ○ ○ ○ ○ ○
150 6 ○ ○ ○ ○ ○
200 8 ○ ○ ○ ○ ○
250 10 ○ ○ ○ ○ ○
300 12 ○ ○ ○ ○ ○

[Fig.-36]

22
 6. 3 Piping Gasket Dimensions
6. 3. 1 Joint sheet gaskets
<Table-11> Joint Sheet Gasket Dimensions
Unit: mm
ANSI FLANGE
Nominal Size JIS FLANGE
ANSI 125,150Lb
D2
mm inch D1 D1 D2
JIS 5K JIS 10K
40 1 1/2 49 83 89 48.5 85.9
50 2 61 93 104 60.5 104.6
65 2 1/2 77 118 124 73.2 124.0
80 3 90 129 134 88.9 136.7
100 4 115 149 159 114.3 174.8
125 5 141 184 190 141.2 196.8 [Fig.-37]
150 6 167 214 220 168.1 222.2
200 8 218 260 270 218.9 279.4
250 10 270 325 333 273.0 339.9
300 12 321 370 378 323.8 409.4
Note) øD1 dimension of 65 mm is the old JIS dimension.

6. 3. 2 Spiral gaskets
<Table-12> Spiral Gasket Dimensions
Unit: mm　　
Nominal Size JIS 10K ANSI 150Lb
mm inch D1 D2 D3 D4 D1 D2 D3 D4
40 1 1/2 48 54 73 89 48 54 73 85
50 2 61 69 88 104 61 69 88 104
65 2 1/2 73 81 100 124 73 81 100 123
80 3 89 97 120 134 89 97 120 136
100 4 115 124 146 159 115 124 146 174
125 5 140 151 177 190 140 151 177 196
[Fig.-38]
150 6 166 178 207 220 166 178 207 222
200 8 217 227 257 270 217 229 257 279
250 10 268 282 318 332 268 285 318 333
300 12 319 331 362 377 319 335 362 409
Note) If minor gas leakage (100 ppm or less) is a problem, please contact our sales department.

6. 3. 3 Punching gasket and PTFE envelope gasket

<Table-13> Available punching gasket and PTFE envelope gasket
Inner diameter PTFE envelope Gasket
Joint Sheet and
Nominal Size permissible (NIPPON VALQUA INDUSTRIES, LTD.,
PTFE punching Gasket (t ≦ 2 mm)
max. dimension Flow-less Gasket (7030,7031,7035 series))
mm inch D JIS 5K JIS10K ANSI 150Lb JIS 5K JIS10K ANSI 150Lb
40 1 1/2 55 ○ ○ ○ ○ ○ ○
50 2 69 ○ ○ ○ ○ ○ ○
65 2 1/2 77 ×＊1 ×＊1 ○ ×＊1 ×＊1 ○
80 3 97 ○ ○ ○ ○ ○ ○
100 4 124 ○ ○ ○ ○ ○ ○
125 5 151 ○ ○ ○ ○ ○ ○
150 6 178 ○ ○ ○ ○ ○ ○
200 8 227 ○ ○ ○ ○ ○ ○
250 10 282 ○ ○ ○ ○ ○ ○
300 12 331 ○ ○ ○ ○ ○ ○
Remarks *1 : These gasket cannot use for 65mm of JIS piping. If use for 65mm, you must choose under 77mm for the inner diameter.
PTFE envelope gasket, NIPPON VALQUA product only available.(In other manufacturers, product size is unavailable.)
23
 6. 4 Piping Bolt Sizes
■ Long bolts and nuts [Indication Example]
8 － M16 × 145 × 16
Long bolt・nut（fully threaded）

H M Quantity
Nominal Size M
Bolt length L (mm)
L
Nut width H (mm)
H: Nut height [Fig.-39]

＜ Table-14 ＞ Piping Long Bolt and Nut Sizes

Nominal Size ASME/ANSI
JIS 5K JIS 10K
mm inch CLASS 150
40 1 1/2 4-M12×100×12 4-M16×120×16 4-1/2-13UNC×115×16
50 2 4-M12×120×12 4-M16×130×16 4-5/8-11UNC×140×16
65 2 1/2 4-M12×120×12 4-M16×145×16 4-5/8-11UNC×155×16
80 3 4-M16×130×16 8-M16×145×16 4-5/8-11UNC×155×20
100 4 8-M16×145×16 8-M16×145×16 8-5/8-11UNC×155×20
125 5 8-M16×145×16 8-M20×170×20 8-3/4-10UNC×175×22
150 6 8-M16×145×16 8-M20×170×20 8-3/4-10UNC×175×22
200 8 8-M20×170×20 12-M20×170×20 8-3/4-10UNC×205×22
250 10 12-M20×190×20 12-M22×190×22 12-7/8-9UNC×215×24
300 12 12-M20×190×20 16-M22×190×22 12-7/8-9UNC×215×24

24
7. TROUBLESHOOTING
7. 1 Troubleshooting
Problem Main Cause Countermeasure
1. Leakage from between After reducing the pressure, loosen the piping bolts, and then
the body and piping The piping bolts are loose or
retighten them by diagonal sequence.
flange faces they were not tightened evenly.
(4. 1. 1-10) “Piping bolt tightening procedures”)

The piping flange face is

scratched or there is waste ma- Remove the valve. Repair and clean the piping flange face. After
terial or other foreign material cleaning, install the valve again. (3. 4. 2-1)
adhering.

The flanges or pipes are mis- Remove the valve. Align the flanges/pipes and make the flanges/
aligned. pipes parallel. (3. 4. 2-6),10))

Loosen the bolts and realign the valve.

The valve is misaligned.
(3. 4. 2-6),10))

No piping gasket is inserted, or Insert a proper gasket between the pipe flange and valve.
improper gasket is inserted. (3. 4. 2-5))
[Fig.-40]
2. Leakage from the gland The gland bolts are loose.
Retighten the gland bolts.
bottom The gland packing has worn out
If leakage is not reduced, replace the gland packing.
or has deteriorated.
The bottom bolts are loose.
If the hexagon bolts are loose, retighten them.
The bottom gasket has deterio-
If leakage is not reduced, replace the bottom gasket.
rated.
When external force caused by a support secured to the valve
The body and shaft have de- body, etc. is applied to the valve in operation, deformation of the
formed. body is possible. Check visually for deformation of the shaft. If
any deformation is observed, valve replacement is required.
If any cracks or breakage are observed on the body, stop use of
The body is damaged.
[Fig.-41] the valve immediately and replace the valve.
3. Valve seat leakage Wrong material was selected
Replace the valve with one made of the proper material.
for the fluid application and the
For details, please contact our sales department.
parts are corroded.

The product specification does

Use the product within the product specifications (temperature,
not meet the requirement for
pressure, flow rate, fluid type).
the fluid.

There is damage to the disc or

When the Seatring is damaged, replace the Seatring.
Seatring due to the presence of
If any abnormality is observed on the disc edge, replace the valve.
foreign material inside the piping.

The full-close position of the

Clean the valve seat and body stopper (3. 6. 3) and adjust the
disc is changed.
full-close position correctly (5. 5). In addition, check that there is
[Fig.-42] (The actuator installation bolts no problem with the actuator output.
are loose, etc.)

There is torsion of the shaft due

to increase in the opening/clos- Replace the valve.
ing torque.

Pressure between the Seatring Loosen the piping bolts and realign the valve and the flange.
and the disc is not even due to un- Then retighten the piping bolts. (4. 1. 1-10) “Piping bolt tighten-
even tightening of the piping bolts. ing procedures”)

Wearing and deterioration of the

Seatring due to long period of
Replace the Seatring.
use or high frequency of open-
ing and closing operations

25
7. 1 Troubleshooting (Continued)
Problem Main Cause Countermeasure

4. The valve does not Insert a short pipe or spacer between the valve and flange to
work. The disc interferes with the pip- avoid interference. (section 6. 1) In this case, remove and check
Faulty operation ing or other devices. the disc sealing part because there is a high possibility that it is
damaged.

Check the appearance of the body, disc and shaft to ensure that
The valve is deformed or dam-
there is no deformation, dent, damage, corrosion, etc. If any of
aged.
these are observed, replace the valve.

Actuator parts are damaged. For details, refer to the instruction manual of the actuator.

The piping bolts are loose or

If tightening force of the bolts is uneven or the contact areas are
tightened unevenly.
not equal, the valve seat compression is uneven and the torque
The valve is misaligned.
may increase. Loosen the bolts and retighten them by diagonal
The pipe flanges are mis-
sequence. (section 3. 4. 2-6),10), section 4. 1. 1-10) “Piping bolt
aligned, are not parallel, or
tightening procedures”)
distorted.

Set the valve to the full-open position and flush the foreign material
Increased torque due to pres-
[Fig.-43] ence of foreign material in the out to remove it.
(section 3.6.6-4)) In this case, remove and check the disc sealing
piping.
part because there is a high possibility that it is damaged.

If rust powder or powdered foreign material is inside the piping, any

Powdered foreign material
foreign material which entered the bearings may interfere with the shaft
inside the piping enters the
rotation.
bearings.
If there is a possibility of this remove the valve and clean it.

For automatic valves, the actuator size is selected in accordance

The product specifications do with the working conditions (temperature, pressure, flow rate,
not conform to the fluid specifi- fluid type). If the working conditions are changed, the valve may
cations. not work due to insufficient actuator torque.
Please contact our sales department.

For cylinders, check the following items.

1) The rated supply pneumatic pressure and the supply amount
are secure.
2) The bypass valve is closed.
3) The operation air stop valve is open.
The actuator rated output is not 4) The speed controller is open properly.
available. 5) The exhaust port plug has been removed.
(For automatic valves) For motors, check the following items.
1) The rated power voltage is supplied.
2) Voltage is applied to the motor properly.
3) The thermal protector, etc. is not activated.
4) Two or more actuators are not operated with one switch.
5) No water is inside the motor.
For details, refer to the instruction manual of each actuator.

If a support is installed to the valve neck section or actuator, the sup-

The valve body is deformed port may produce a force that deforms the valve.
because abnormal force is ap- Remove the support member and check the valve.
plied. If this product interferes with other devices or buildings, the force is
produced too. Avoid the interference of the product.

Abnormal interference of the Replace the Seatring.

disc due to damage or deforma- If any abnormality is observed on the disc edge, replace the
tion of the Seatring. valve.

If none of the above are applicable, the valve parts may be dam-
Parts, such as the disc, shaft,
aged, and replacement of the parts may be required. Please
body and joint, are damaged.
contact our sales department.

26
 MEMO

27
 WARRANTY PERIOD
The warranty period of the delivered product should be eighteen (18) months after shipment from our factory or
one (1) year after the date of starting trial operation, whichever comes first.

SCOPE OF WARRANTY AND INDEMNITY

If any damage or problem should occur during the foregoing warranty period due to our fault, TOMOE VALVE will
replace or repair any defective part of the product free of charge at the place where the product was purchased or
where it was delivered (limited to Japan).
However, warranty is not applicable if the causes of defects should result from the following:
1) The failure was caused by inappropriate conditions, environment, handling or use methods, etc. which are not
specified in the catalog, specifications or other relevant documents that had been made and entered into be-
tween the customer and TOMOE VALVE.
2) The failure was caused by a product other than the delivered TOMOE's product.
3) The failure was caused by modifications or repairs by a party other than TOMOE VALVE.
4) The failure was caused by use under the condition that had not been given as required specifications of valves,
etc., or by a problem that was not foreseen from the specified conditions.
5) The failure was caused by significant wear and tear of the Seatring, gland packing, etc.
6) The failure was caused by poor application of lubricant, etc. to the spare parts.
7) The failure was caused by improper maintenance or inspection under highly frequent valve opening/closing
operations.
8) The failure was caused by power supply or air supply.
9) The failure was caused by foreign material, such as dust, that entered and clogged in the product.
10) The failure was caused by improper storage of the product, such as open air storage.
11) The failure was caused by fire, flood, earthquakes, fall of rocks, and other natural disasters.
12) The failure was caused by other reasons which are not our responsibility.
In addition, the forgoing warranty is only applicable to the product itself and excludes compensation of any other
indirect or consequential damage.

CHARGED REPAIR SERVICE AND SUPPLY OF DISCONTINUED PARTS

Products are subject to discontinuation or modification without notice. For products that are no longer manufac-
tured or sold, repair or overhaul of the products may not be available after 5 years since discontinuation. In addi-
tion, please note that supply of the parts or spare parts of the products may not be available. 消耗部品の交

REPLACEMENT TIMING OF SPARE PARTS

Replace the spare parts around after 3000 times of opening and closing (Open - Close - Open: 1 time) or one year
operation at room temperature using fresh water. The replacement timing may become faster depending on the
working environment. Please replace the spare parts based on the number and term.

APPLICABLE APPLICATION CONDITIONS

When the products are exported to overseas countries, perform checks in accordance with the acts (Foreign Ex-
change and Foreign Trade Act, etc.) by Ministry of Economy, Trade and Industry.

www.tomoevalve.com
●Head Office
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Telephone: 81-6-6110-2370 Telefax: 81-6-6110-2371 E-mail: [email protected]

Global Sales Operations * "Before placing an order" has been described since 25 May, 2005.
TOMOE VALVE INDUSTRY (NANTONG) CO., LTD. http://www.tomoe.sh.cn
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Telephone: +86-21-52715628 Telefax: +86-21-52653691 E-mail: [email protected]

TOMOE VALVE LIMITED www.tomoeeurope.co.uk ■ CONTACT

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Newport, South Wales NP19 4ST, United Kingdom
Telephone: 44-1633-636800 Telefax: 44-1633-636801 E-mail: [email protected]

TOMOE VALVE ASIA PACIFIC PTE. LTD. www.tomoe.com.sg

No 2, Toh Guan Road East, #02-02, Singapore 608837
Telephone: +65-68995060 Telefax: +65-68995061 E-mail: [email protected]

TOMOE VALVE (THAILAND) CO., LTD.

No. 317, Kamol Sukosol Building, Unit B, 12th Floor, Silom Road, Silom Sub-district, Bangrak District, Bangkok 10500, Thailand
Telephone: +66-(0)-2117-0429 Telefax: +66-(0)-2117-0148 E-mail: [email protected]

PT. TOMOE VALVE BATAM http://www.tomoe-batam.com

BlockF2 Latrade Industrial Park, JI. Sei Binti Tanjung Uncang, Batam 29422 Indonesia
Telephone: +62-778-395-466 Telefax: +62-778-396-475 E-mail: [email protected]

TOMOE USA Inc.

15700 International Plaza Drive Suite150, Houston TX, 77032 USA
Telephone: +1-281-358-7571 Telefax: +1-281-358-7861 Cat.No.EG1402-③ 2018.10.31-Ph