GEAR OPERATOR INSTALLATION & REVERSAL STEP 1 Use of well lubricated

BUTTERFLY VALVE ADAPTER SQUARE INDICATOR CAP

bolts & flat washers are required.
An anti-seize thread lubricant
Installation Instructions NUT HANDLE
ADAPTOR HEX HEAD CAP SCREW (IMS Copperflake or equivalent)
is highly recommended.
HAND GEAR OPERATOR
BF-3A-0410 WHEEL

Spears® Butterfly Valves are designed for STOP SEE BOLT SPECIFICATION TABLES AT THE END OF THESE INSTRUCTIONS
the system connection either between two ADJUSTMENT FOR SELECTION OF PROPER BOLT, SIZE & QUANTITIES
flanges, or with single-side (flange one
side only) connection for dead-end service.
SCREWS (2)
* DRIVE BUSHING STEP 2 Place the valve and handle in a closed position. Place a user-
OVERSIZE
Valve can be installed for flow in either DRIVE supplied 1/8” gasket having a shore “A” durometer of approximately 60
direction in a dual-flange installation. BUSHING
SPLINE
* between the valve body and flange, align the bolt holes of the mating flanges
STEM and gasket. Insert all bolts, washers, and nuts.
Spears® Standard Butterfly Valves (12” &
smaller) accept field installable lug insert AT THIS TIME, BE SURE THAT THE FLANGE
AND GASKET SURFACES ARE FLUSH AND SQUARELY ALIGNED.
sets for quick conversion to a lug style. GEAR
Attention to direction of flow is required when installed with single-side flange OPERATOR Tighten the nuts by hand until they are snug.
connection. Spears® True Lug Butterfly Valves offer factory installed lugs which MOUNT
BOLTS (x 4)
allow flange connections from either side, regardless of direction flow. STEP 3 Using a 180° opposing sequence,
VALVE BODY
This instruction covers general Installation for all Spears® PVC, CPVC, & PP tighten flange bolts in 5 ft-lb increments to required
Butterfly Valves. All applicable instructions and procedures should be read specifications (See Torque Sequence Chart).
thoroughly before starting. Suitability of the intended service application should STEP 1 GEAR OPERATOR HAND WHEEL INSTALLATION: Place hand wheel
be determined before installation. Plastic piping systems should be engineered, hub over square handle adaptor and install the adaptor nut. Torque to 10 ft-lb.
installed, operated & maintained in accordance with accepted standards and DO NOT USE BOLTS TO BRING TOGETHER IMPROPERLY MATED
procedures for plastic piping systems. TO REVERSE THE GEAR OPERATOR POSITION 180°: Set the valve in the open FLANGES.
position. Remove the 4 mounting bolts & flat washers that secure the gear
CAUTION: Connecting Flanges must have an inside diameter not less than that operator to the valve body, lift the assembly & drive bushing from the valve TRUE LUG BUTTERFLY VALVE INSTALLATION
of PVC Schedule 80 Pipe (ASTM D 177-85) to maintain operation clearance stem. NOTE: Drive bushing is timed to operator with a single oversize spline
with the disc. Flange bolt pattern conforms to ANSI Class 125/150. tooth & index mark. Turn gear operator assembly 180° and reinstall onto valve Connects from either side, regardless of direction flow.
stem being sure to align bushing oversize spline with its matching oversize STEP 1 With the valve in the closed position, place
IMPORTANT: Read Precautions & Warnings for all Valve Installations at groove in the gear operator. Reinstall all mounting bolts & flat washers, and
the end of these instructions. It is absolutely necessary that all design, torque to 10 ft-lb. user-supplied gasket and pipe-mounted flange on the
installation, operation & maintenance personnel be trained in proper desired side of the valve body. Insert the proper size &
handling, installation requirements and precautions for installation & use STEP 2 GEAR OPERATOR POSITION ADJUSTMENT: Remove 2 rubber length hex head bolts (see Bolt Specification Chart at
of plastic piping systems before starting. the end of these instructions) with flat washers, through
grommets from end of Gear Operator housing adjacent to the “OPEN” the pipe-mounted flange and gasket. Hand thread hex
designation, to allow access to the “stop adjustment screws”. head bolts into lug inserts.
HANDLE INSTALLATION & REVERSAL
CLOSED CLOSED POSITION: Rotate Hand Wheel to full closed position. AT THIS TIME, BE SURE THAT THE FLANGE
Measure distances from both leading edges of the disc AND GASKET SURFACES ARE FLUSH AND
The Valve Handle (or optional Gear Operator) can be installed for either left (perpendicular to stem) to the gasket sealing surface on
or right side operation. CAUTION: Do not remove Orange Disc Timing-Stop SQUARELY ALIGNED.
Equal
the seat side of the valve. These distances should be equal
Plate located below handle assembly. Distance
Each when properly adjusted for the closed position. If not, use an Tighten the bolts by hand until they are snug.
Allen wrench to adjust the stop located on the “O” side of the
Side
HANDLE INSTALLATION: Open valve and check axial displacement & disc clearance. No more than
“OPEN” designation until proper position is reached. Reinstall
HANDLE COVER Place handle and bushing over rubber grommets in operator housing. 1/8” displacement on the pipe centerline is allowed.
HEX
HEAD metal stem in one of two desired
BOLT positions being sure that arrows on OPEN OPEN POSITION: Rotate Hand Wheel to the full open position. STEP 2 Using a 180° opposing OPEN
valve body match direction of pointer
(ENLARGED)
FLAT Disc should be positioned squarely at 90° to valve body sequence, tighten flange bolts FLANGE
WASHER on handle body. Install hex nut & flat when properly adjusted for the open position. If not, use an in 5 ft-lb increments to required
washer onto top of stem, tighten and Allen wrench to adjust the stop located on the “N” side of the specifications (See Torque
HANDLE torque to 40 in-lb. Snap cover back “OPEN” designation until proper position is reached. Reinstall Sequence Chart). VALVE
BUSHING
to handle body. rubber grommets in operator housing. BODY

HANDLE To reverse the Handle position by

BODY
180°, first set valve to the fully open BOLT PREPARATION FOR ASSEMBLY
SINGLE SIDE BOLT &
position. Remove the snap-in cover FLANGE FLAT WASHER
from the top of the handle to expose Once a flange is attached to the pipe or valve, the method of joining two CONNECTION USER

the retaining nut, remove it & the flat flanges is as follows: SUPPLIED
GASKET
washer. Lift handle & handle bushing LUBRICATION WARNING: Some Lubricants,
VALVE assembly from valve stem, reposition including vegetable oils, are known to cause
BODY handle 180° on valve stem, reinstall stress cracking in thermoplastic materials.
flat washer & retaining nut, torque to DO NOT USE BOLTS TO BRING TOGETHER
Formulation changes by lubricant manufacturers IMPROPERLY MATED FLANGES.
40 in-lb. Snap cover back into place. may alter compatibility of previously acceptable
materials and are beyond our control.

1 2 3

STANDARD LUG BUTTERFLY VALVE INSTALLATION BUTTERFLY VALVE POLYPROPYLENE BUTTERFLY VALVE
(And Lug Insert Installation) BOLT SPECIFICATION TABLE
Valve No. of Bolt Bolt Valve Lay
Lug Insert-style Butterfly Valves require attention to Size Bolt Diameter Torque Length Bolt Lengths
FLOW direction. Mating Flange must be placed on side PVC & CPVC STANDARD BUTTERFLY VALVE (in.) Holes (in.) (ft.lbs.) (in.)
of valve opposite the Lug Insert hex recesses. Valve No. of Bolt Bolt Lengths1 (in.) Bolt Bolt Flat
Size Bolt Torque Dual Diameter Threads Washer 1-1/2 4 1/2 12 1-9/16
For installation of Standard Lug Butterfly Valves or Lug Single Side Bolt Lengths will vary according
Insert Sets, pass lug inserts through each bolt hole from Typical (in.) Holes (ft.-lbs.) Flange 3 (in.) per inch O.D. (in.) 2 4 5/8 25 1-7/8
Lug Insert to thickness of valve, mating
the side of the valve body containing the hex recesses. (Shape may vary 1-1/2 4 12 3-1/4 4-1/4 1/2 13 1-3/8 2-1/2 4 5/8 25 2-1/16 flanges, washers, nuts and
Press lightly until the lug insert is fully seated into the with size). 2 4 25 3-3/4 4-3/4 5/8 11 1-3/4 gaskets used.
recess. 3 4 5/8 25 2-1/8
2-1/2 4 25 4-1/4 5-1/4 5/8 11 1-3/4
Install Pipe-Mounted Mating Flange on side of valve opposite the Lug Insert Hex 4 8 5/8 25 2-5/16 The following formula may be
3 4 25 4-1/4 5-1/2 5/8 11 1-3/4 used to calculate bolt length for
recesses. Secure with the proper size & length hex bolts & flat washers from 6 8 3/4 40 2-3/4
opposing side of hex recesses. Pass bolts with washers through flange, gasket 4 8 25 4-1/2 5-3/4 5/8 11 1-3/4 installation with mating flange
6 8 40 5-1/4 6-3/4 3/4 10 2 8 8 3/4 40 3 each side:
and thread into Lug Insert. (See Bolt Specification Chart in next column).
8 8 40 5-3/4 7-1/4 3/4 10 2 10 12 7/8 64 3-1/4
Tighten the nuts by hand until they are snug. AT THIS TIME, BE SURE THAT THE L=V+2(F+G+W)+N
FLANGE AND GASKET SURFACES ARE FLUSH AND SQUARELY ALIGNED. 10 12 64 6-1/2 8-1/4 7/8 9 2-1/4 12 12 7/8 95 3-1/2
Using a 180° opposing sequence, tighten flange bolts in 5 ft-lb increments to 12 12 95 6-3/4 8-1/2 7/8 9 2-1/4 14 12 1 110 6-1/4 L = Minimum Bolt Length
required specifications (See Torque Sequence Chart). 14 12 110 9-1/2 or 10 12 1 8 2-1/2 16 16 1 110 6-3/4
V = Valve Lay Length
F = Flange Thickness
18 16 1-1/8 110 7-1/8 G = Gasket Thickness
HEX RECESSES PVC & CPVC BUTTERFLY VALVE WITH LUG INSERT
20 20 1-1/8 110 7-3/4 W = Washer Thickness
Valve No. of Bolt Bolt Lengths1 (in.) Bolt Bolt Flat N = Nut Thickness
VALVE BODY Size Bolt Torque 2nd Diameter Threads Washer 24 20 1-1/4 110 8-1/2
USER-SUPPLIED GASKET (in.) Holes (ft.-lbs.) Single Side Flange2 (in.) per inch O.D. (in.)
1/8” FULL FACED 1-1/2 4 12 1-3/4 1-1/2 1/2 13 1-3/8
2 4 25 2 1-3/4 5/8 11 1-3/4
PRECAUTIONS AND WARNINGS
2-1/2 4 25 2-1/4 2 5/8 11 1-3/4 CAUTION: The system must be designed and installed so as not to pull the
3 4 25 2-1/4 2 5/8 11 1-3/4 components in any direction. Pipe system must be cut and installed in such
4 8 25 2-1/2 2 5/8 11 1-3/4 a manner as to avoid all stress loads associated with bending, pulling, or
LUG INSERT shifting. All piping systems must be supported.
6 8 40 3-1/4 2-1/4 3/4 10 2
FLANGE MUST BE 8 8 40 3-3/4 2-1/4 3/4 10 2 DO NOT ATTEMPT TO DRAW TOGETHER ANY GAPS
INSTALLED THIS SIDE 10 12 64 4 3 7/8 9 2-1/4 WITHOUT ALLOWING FREE MOVEMENT TO ONE SIDE OF THE
BOLT & FLAT WASHER 12 12 95 4-1/4 3 7/8 9 2-1/4 SYSTEM CONNECTION. ADJUST VALVE POSITION AS NECESSARY.
14* 12 110 7 3-1/2 1 8 2-1/2
*14” CPVC Lug Insert not available
NOT FOR DISTRIBUTION OF COMPRESSED AIR OR GAS.
TORQUE SEQUENCES PVC & CPVC TRUE LUG BUTTERFLY VALVE
WARNING: All air must be bled from the system during the initial fluid fill.
Valve No. of Bolt Bolt Bolt Lug Flat Pressure testing of the system must not be made until all solvent cement joints
Size Bolt Torque Lengths1 Diameter Threads Washer have properly cured. Initial pressure testing must be made at approximately
(in.) Holes (ft.-lbs.) (in.) (in.) per inch O.D. (in.) 10% of the system hydrostatic pressure rating to identify potential problems
1-1/2 4 12 1-1/2 7/16 14 1-1/4 prior to testing at higher pressures.
2 4 25 1-1/2 1/2 13 1-3/8
2-1/2 4 25 1-3/4 1/2 13 1-3/8
3 4 25 2 1/2 13 1-3/8
Flange Recommended 4 8 25 2 1/2 13 1-3/8
Size Torque 6 8 40 2-1/4 5/8 11 1-3/4
(in.) (ft. lbs.) 8 8 40 2-1/4 5/8 11 1-3/4
10 12 64 2-3/4 3/4 10 2
1/2 - 1-1/2 12
12 12 95 2-3/4 3/4 10 2
2-4 25 14* 12 110 3-1/2 1 8 2-1/2 SPEARS® MANUFACTURING
5 30 COMPANY
*14” CPVC True Lug not available CORPORATE OFFICE
6-8 40 1: Minimum bolt lengths based on use of Spears® flanges, 1/8” full faced gaskets, 15853 Olden Street, Sylmar, CA
10 64 standard S.A.E. hex bolts and Standard Plate “W” Series flat washers. 91342
2: Specified bolt lengths are maximum allowable for maintaining proper clearance in PO Box 9203, Sylmar, CA 91392
12 95 initial Single-Side installation with Lugs where anticipated 2nd Flange installation option (818) 364-1611
is to be retained without removal of valve. www.spearsmfg.com
14 - 24 110 3: Minimum bolt length through 2-flanges, 2-gaskets,2-flat washers and 1-valve body.
© Copyright 2010 Spears® Manufacturing Company. All Rights Reserved.
4 5 Printed in the United States of America 04/10. BF-3A-0410