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Leslie K-MAX Installation, Operating, And Maintenance Instructions Parts List

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12501 Telecom Drive, Tampa Florida 33637
ROTARY CONTROL VALVES
1" - 8"
ANSI CLASS 150 - 600
DIN 16 - 40
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
MOUNTING POSITION . . . . . . . . . . . . . . . .A1
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . .A1
FLANGED VALVE INFORMATION . . . . . . . .A1
GASKETS . . . . . . . . . . . . . . . . . . . . . . . . . .A1
BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
SUPPLY AIR CONNECTIONS . . . . . . . . . . .A1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
SYSTEM FLUSH . . . . . . . . . . . . . . . . . . . . .A1
START-UP . . . . . . . . . . . . . . . . . . . . . . . . .A1
PACKING . . . . . . . . . . . . . . . . . . . . . . . . . .A1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
LUBRICATION . . . . . . . . . . . . . . . . . . . . . .A3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . .A3
PACKING REPLACEMENT . . . . . . . . . . . . .A3
VALVE DISASSEMBLY . . . . . . . . . . . . . .A5-A6
VALVE REASSEMBLY . . . . . . . . . . . . . .A6-A7
SEAT RING LAPPING . . . . . . . . . . . . . . . . .A7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .A8-A9
CODE SELECTION CHART . . . . . . . . . . . . . . . . .A10
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . .A11-A12
ILLUSTRATION INDEX
Figure 1 - Actuator Mounting Positions . . . . . . . . . .A2
Figure 2 - K-Max Parts Identification . . . . . . . . . . .A4
Figure 3 - Packing Component Stackup . . . . . . . . .A5
Table A - K-Max Seat Retainer Torques . . . . . . . . .A6
Figure 4A & 4B - Dimensions & Parts List . . . . . . .A11
Figure 5 - Valve Seat Retainer Wrench . . . . . . . . .A13
INSTALLATION, OPERATING,
AND MAINTENANCE INSTRUCTIONS
PARTS LIST
LESLIE CLASS K-MAX

TABLE OF CONTENTS

DIAPHRAGM ACTUATORS
ON K-MAX CONTROL VALVES
MODELS 40, 55 AND 85
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . .B14
AIR SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B14
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .B14
CLOSED STOP ADJUSTMENT . . . . . . . . .B14
OPEN STOP ADJUSTMENT . . . . . . . . . . .B15
CLOSED STOP ADJUSTMENT . . . . . . . . .B15
OPEN STOP ADJUSTMENT . . . . . . . . . . .B15
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .B15
INSTALLATION . . . . . . . . . . . . . . . . . . . . .B16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . .B16
INSTALLATION . . . . . . . . . . . . . . . . . . . . .B16
SPRING ASSEMBLY REPLACEMENT . . . . . . . . .B17
DIAPHRAGM REPLACEMENT . . . . . . . . . . . . . . .B18
REVERSING THE ACTION . . . . . . . . . . . . . . . . . .B18
CHANGING MOUNTING POSITIONS . . . . . . . . . .B19
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B21
ILLUSTRATION INDEX
Figure 1- Vibration Support & Disassembly Studs .B14
Figure 2A- Size 40 Actuator Cutaway . . . . . . . . . . .B15
Figure 2B- Size 55/85 Actuators-Reverse Action .B15
Figure 3- Size 40 Actuator/Spring-To-Close Mode B16
Figure 4- Coupling Clamp Screws . . . . . . . . . . . .B17
Figure 5- Actuator Mounting Positions . . . . . . . . .B17
Figure 6- Link Arm Position . . . . . . . . . . . . . . . . .B19
Figure 7- Stub Shaft Position . . . . . . . . . . . . . . . .B19
Figure 8- Parts Identification for 55 & 85 Actuator .B20
Figure 9- Exploded Drawing of 55 & 85 . . . . . . . .B21
Figure 11- DR 40 Actuator Assembly . . . . . . . . . .B22
9/0.5.0
Rev.2
Formerly D-10236

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  • Page 1: Table Of Contents

    Figure 4- Coupling Clamp Screws ... .B17 Figure 2 - K-Max Parts Identification ...A4 Figure 5- Actuator Mounting Positions ..B17 Figure 6- Link Arm Position .

  • Page 2: Introduction

    It is recommended that one set of Recommended Spare parts be inventoried for each valve size and type. Recom- The K-MAX Rotary Control Valve is a high performance rotary mended Spare Parts are identified on the Assembly Drawing. Control valve designed to meet an wide range of applications.

  • Page 3: Installation

    I. INSTALLATION Supply air should be clean, dry and oil free and must not exceed the maximum rating of the actuator spring; see the This installation section has been broken down into data plate affixed to the actuator spring case. subsections that present a wide range of installation related requirements.
  • Page 4 ACTUATORS ARE IN THE FOREGROUND. VALVE BODIES ARE BEHIND THE ACTUATORS. DIRECT ACTING ACTUATORS (SPRING-TO-OPEN) 90° FROM STANDARD 180° FROM STANDARD STANDARD 270° FROM STANDARD REVERSE ACTING ACTUATORS (SPRING-TO-CLOSE) 90° FROM STANDARD STANDARD 180° FROM STANDARD 270° FROM STANDARD (1) FLOW TENDING TO OPEN VALVE - PREFERRED FOR VALVES WHICH MUST FAIL OPEN (2) FLOW TENDING TO CLOSE VALVE - PREFERRED FOR VALVES WHICH MUST FAIL CLOSED ACTUATOR MOUNTING POSITIONS FIGURE 1...

  • Page 5: Maintenance

    See Figure 2, Page A4 for parts identification. WARNING Depressurize and drain the process line. UNLESS OTHERWISE SPECIFIED THIS Remove the actuator from the valve as described in the VALVE HAS BEEN LUBRICATED AT THE ACTUATOR REMOVAL Section of the Actuator FACTORY WITH LITHIUM AND SILICONE Instruction manual.
  • Page 6 PARTS LIST FOR K-MAX VALVE PART NAME UPPER GUIDE BEARING PLUG LOWER GUIDE BEARING GUIDE BUSHING (3’ THRU 8” VALVES) PIPE PLUG BODY SEAT RING SEAT RETAINING RING FLANGE RETAINING RINGS SEPARABLE FLANGES BACKUP RING PACKING PACKING GLAND YOKE/BODY STUD...

  • Page 7: Valve Disassembly

    PACKING COMPONENT STACKUP FIGURE 3 Remove the two nuts that secure the actuator yoke (not shown in Figure 2, Page A4) to the valve body, then lift WARNING the yoke and packing gland clamp off the valve. THIS VALVE IS A PRESSURE VESSEL. LINE Slide the packing gland off the valve shaft.

  • Page 8: Valve Reassembly

    Figure 3, Page A5, being sure to use the proper lubricant if required. Then slide the packing gland into place. K-MAX SEAT RETAINER TORQUES TABLE A While holding the packing gland clamp inside the actuator yoke (with ball bearings), slide the packing 18.

  • Page 9: Seat Ring Lapping

    F. SEAT RING LAPPING, CONTINUED 22. Install the accessories removed in Step 4 of the DISASSEMBLY Section of this instruction. Separate the seat ring and plug, then wipe off the 23. Install the valve in the pipeline and connect the lapping compound.

  • Page 10: Troubleshooting

    TROUBLESHOOTING The following list identifies problems with some suggestions as to what may be causing the problem. Refer to the applicable sections of the Valve, Actuator and Positioner Instructions for detailed procedures on repairing or replacing components. IF... THEN... Excessive flow through Low supply air pressure to direct acting actuator.
  • Page 11 TROUBLESHOOTING, CONTINUED IF... THEN... Actuator dies not respond to Ruptured diaphragm in actuator or positioner. Replace and recalibrate. changes in Instrument Signal Loss of supply air pressure. Restore. Valve shaft packing is too tight. Loosen packing nuts. Debris in valve interfering with plug movement. Clean and recalibrate. Positioner faulty or improperly adjusted.

  • Page 12: Code Selection Chart

    Code Selection Chart Class Material Valve Valve Trim Trim Shutoff Packing Flow Actuator Spring H.O.D. Actuator Size Conn. Rating Material Factor Class Direction Bolting Class - Position 1 & 2 Trim Factor - Position 8 1 = Full 6 = 0.6 Material - Position 3 4 = 0.4 C = Steel WCB...

  • Page 13: Parts List

    KM5000208 KM1219430 KM1205155 KM1203954 — — Consult Leslie * Recommended spare parts * Consult factory for o-ring type guide bushings, Ref. A1 & A3. * Always reference serial number when ordering parts Also for Teflon-insert seatring Ref. A23. Page A11...
  • Page 14 — — — KM1147239 KM1147239 KM1147242 KM1147242 A4 * Bushing (Plug) Trim T3 — — — KM1203957 KM1203957 KM1203632 Consult Leslie Pipe Plug BMtl CS KM1192699 KM1192699 KM1192699 KM1192699 KM1192699 KM1192699 KM1192699 Pipe Plug BMtl S2 KM1192698 KM1192698 KM1192698 KM1192698...
  • Page 15 INCHES PART NAME MATERIAL QTY. DIMENSIONS DRAWING VALVE MILLIMETERS CARBON STEEL UNPLATED NUMBER SIZE DISC CARBON STEEL ANSI 1018 .187 .850 KEY STOCK M2 TOOL STEEL A-27099-1 1-3/16 .200 3/16 x 3/8 .188 .840 .187 1.225 A-27099-2 1-1/2 1-1/2 .200 3/16 x 3/8 .188 1.215...

  • Page 16: Description

    The Leslie Rotary Diaphragm Actuator is designed for the The spring rating is either 20 psi, 35 psi or 60 psi and is Leslie K-MAX rotary control valves. It can be used for on-off specified on the label affixed to the diaphragm cover.

  • Page 17: Open Stop Adjustment

    13. Slide the coupling off the valve shaft. To remove the diaphragm Actuator properly and safely from a Leslie K-Max Control valve, carefully follow this procedure. ACTUATOR INSTALLATION OF SIZE 40 ACTUATOR 1. Turn the valve shaft counterclockwise until the valve is In 1.

  • Page 18: Size 55 And 85 Actuators

    To remove the Diaphragm Actuator properly and safely from a SIZE 55 AND 85 ACTUATOR Leslie valve, carefully follow this procedure. 1. Set the valve in the closed position. The valve-closed 1. Stop pipeline flow. Pipeline flow must be stopped before position is described in the Valve instruction.
  • Page 19 COUPLING CLAMP SCREWS (Size 40 only) FIGURE 4 9. Position the stub shaft as shown in Figure 4. Turn the stub 6. Connect the actuator piping. shaft only, not the link arm. 7. Apply air pressure to the diaphragm to slide the rod end 10.

  • Page 20: Spring Assembly Replacement

    12. Relieve the pressure to the diaphragm. 13. Remove the rod end from the old spring assembly and screw it into the new spring assembly until about 1/4” of 13. Attach the pointer to the stub shaft. threads remain showing. 14.

  • Page 21: Changing Mounting Positions

    LINK ARM POSITION STUB SHAFT POSITION FIGURE 6 FIGURE 7 10. Turn the actuator upside down from its previous position CHANGING MOUNTING POSITIONS and fasten it in place. The housing face that faced away from the valve will now be bolted to the bonnet. The actuator may be mounted in any of four positions: 11.
  • Page 22 ENLARGED DETAIL A SEE DETAIL A PARTS IDENTIFICATION FOR 55 & 85 ACTUATOR FIGURE 8 PAGE B20...
  • Page 23 K-MAX - ACTUATOR PARTS 55 ACTUATOR 85 ACTUATOR PART # DESCRIPTION VALVE PART # DESCRIPTION VALVE KM1204998 COVER ASSY DIAPH LIN/ROT KM1105195 COVER ASSY DIA85 KM1008224 SCR HX HD 3/8-16X1 18-8 KM1008224 SCR HX HD 3/8-16x7/8 KM1031950 NUT HX 3/8-16...
  • Page 24 K-MAX - ACTUATOR PARTS 40 ACTUATOR PART PART NUMBER DESCRIPTION VALVE NUMBER DESCRIPTION VALVE KM1181042 COVER ASSY 40 DIR B24* A74277 ORNG, BUNA-N KM1047749 SCR HX HD 5/16-18X3/4 18 KM1117666 BRG SLV, 1. 503X1 . 754x3/8 KM1115425 POINTER DR40 KM1031951 NUT HX.

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