Installation, Operation and Maintenance Instructions
Cast Iron Ball Valves
Valve IBV-125 IBV-E-125
Size (Standard) (Epoxy Coated) Repair Kit
2” 6P-208-01 6Q-208-01 6P-028-01
2-1/2” 6P-209-01 6Q-209-01 6P-029-01
3” 6P-200-01 6Q-200-01 6P-020-01
4” 6P-20A-01 6Q-20A-01 6P-02A-01
6” 6P-20C-01 6Q-20C-01 6P-02C-01
8” 6P-20E-01 6Q-20E-01 6P-02E-01
10” 6P-20G-01 6Q-20G-01 6P-02G-01
This manual presents guidelines for the Installation,
Operation and Maintenance of Conbraco’s Full Port Cast
Iron Ball Valve, the IBV-125 Series. Review the entire
manual before beginning any work.
Proper valve selection is the first step in any successful
installation. Refer to the "Conbraco’s Cast Iron Ball
Valve" catalog for application guidance or contact your
distributor or the factory for more detailed assistance.
A leading cause of premature valve failure is poor
house-keeping. Inspect the piping system prior to valve
installation, whenever possible, to insure that it has been
properly flushed and cleared of construction and
fabrication debris. The seating surfaces in soft seated
valves are particularly susceptible to weld slag and sand
blasting grit. Pipe scale, metal chips and other foreign
materials should be removed.
Prior to installation, remove the valve from its packing
and remove any end covers. Examine the flow bore for
debris. All of Conbraco’s ball valves are shipped in the
open position to prevent damage to the ball surface.
Any foreign matter must be removed. Do not install a
>Flanged End Valve Installation<
After determining that the valve is in good condition,
attention should be given to the flange face. Dents and
heavy scratches should be repaired. Do not install
Conbraco’s Cast Iron Ball valves may be installed in any
position using standard pipe fitting practices. Special
considerations are required when bolting cast iron
valves to steel flanges. When Class 125 CI valves are
to be bolted to Class 150 steel flanges, the steel flanges
shall be flat faced. Due to the brittle nature of cast iron,
consideration should also be given to proper piping
The IBV-125 series features quarter turn operation; full
open to full closed. Standard operation is clockwise to
close. Valves 2” through 6” are furnished standard with
a lever operator. The 8” and 10” valves have gear
operators and handwheels as standard. Gear Operators
are available for all sizes.
Due to its simplicity, the only preventive maintenance is
to periodically inspect the valve for leaks and ease of
operation. Do not disassemble or remove any part
from a valve under pressure. Before removing a
valve from the line, place it in the half-open position to
remove any line pressure or pressure trapped in the
The stem packing was adjusted at the factory to provide
a leak-tight seal when the valve was new but,
compaction can occur within these seals that makes readjustment
necessary. Stem leakage should be stopped
as soon as it is detected. Adjust the packing gland bolts
per the following table:
Valve Gland Bolt Torque
Size Size (max.)
2” 3/8”-16UNC 20 ft-lbs
2-1/2” 3/8”-16UNC 20 ft-lbs
3” 3/8”-16UNC 20 ft-lbs
4” 3/8”-16UNC 20 ft-lbs
6” 1/2”-13UNC 45 ft-lbs
8” 1/2”-13UNC 45 ft-lbs
10” 5/8”-11UNC 93 ft-lbs
Do not over tighten. Over-tightening will result in
excessive operating torque. If stem leakage continues,
or operating torque becomes excessive, de-pressurize
the valve and replace the stem seals. Obtain repair kits
from the factory.
Valves with high operating torque not resulting from
stem seal over-tightening or valves which have leakage
past the seats may have damaged seats or ball
surfaces. These valves should be de-pressurized,
removed from the piping system, disassembled and
inspected for damage.
The first step is to contact your distributor to acquire an
appropriate rebuild kit. These kits contain a complete
set of seats, seals and gaskets.
1. Assure appropriately sized wrenches and lifting
devices are available.
2. Place the valve in the half-open position, assuring
no pressure is trapped in the valve body.
3. Remove the handle or valve operator.
4. Remove the packing gland fasteners, gland plate
and gland ring.
5. Remove the body bolts and remove the tail piece
from the valve body.
6. Using an appropropriate lifting device, remove the
ball from the body cavity.
7. Remove the stem from the valve body. Due to
presence of corrosion products it may be necessary
to drive the stem from the valve body using a soft
face hammer, being careful not to damage the
Note: If replacement of the body or ball is required, we
recommend replacement of the entire valve.
1. Thoroughly clean all the components in preparation
2. Examine the sealing surfaces within the body. If
these surfaces are pitted or deeply scratched the
valve must be replaced. A scratch is anything you
can feel with your fingernail. Machining marks may
be present and will not interfere with sealing.
Scratches that can be seen but not felt may be
polished out using #120 grit emery cloth or finer.
3. Examine the stuffing box. Polish these surfaces
with #120 (or finer) grit emery cloth and inspect for
pits and scratches. Deep scratches running down
the side of the stuffing box will necessitate the
replacement of the valve.
4. Examine the stem. Machine marks may be present
extending around the part. These will not interfere
with effective sealing. If longitudinal scratches or
pitting is present, the stem must be replaced.
5. If the ball has pits or scratches as described above,
it should be replaced.
6. Inspect the spare parts provided to assure they are
correct, in good condition and have not suffered
damage in storage or shipment.
1. Use a lubricant which is recommended for the
intended service. Only small amounts of assembly
lubricants are necessary.
2. Lubricate the new seats and install them in the body
and tail piece.
3. Lubricate the stem. Install the thrust washer on the
stem and install the stem in the body.
4. Lubricate the new stem packings and place them
one at a time over the stem and push them to the
bottom of the stuffing box.
5. Lubricate the gland ring and install with the original
gland bolts provided they are in good condition.
Tighten only finger tight at this time. Rotate the
stem to the closed position.
6. Place the body with the cavity facing upward. Lower
the ball into the body cavity making sure the stem
slot in the ball aligns with the tang on the stem. The
ball should come to rest on the body seat.
7. Set the new body gasket in place.
8. Set the tail piece onto the body. On larger tail
pieces use appropriate lifting equipment to set the
tailpiece. Lift the tail piece by opposite pipeline
flange bolt holes and lower it onto the body. It may
be necessary to use a heavier grease on the tail
piece seat to hold it in its place during this step.
9. Align the pipeline flange bolt patterns (two-hole).
10. Install the body fasteners hand tight. Torque to the
value indicated in the table below in three equal
steps using a criss-cross pattern.
11. Torque the packing gland fasteners to the level
indicated in the section >Valve Adjustments<.
12. Install the operating mechanism, lever or gear, in its
original orientation. Cycle the valve three to five
times to assure smooth operation.
13. Complete the re-assembly with a check of the body
bolt torque by going around the bolt pattern
clockwise at the specified level. Check the packing
gland fasteners torque again at this time.
14. The valve is now ready for testing and use.
Valve Body Bolt Torque
Size Size (max.)
2” 1/2”-13UNC 45 ft-lbs
2-1/2” 1/2”-13UNC 45 ft-lbs
3” 1/2”-13UNC 45 ft-lbs
4” 1/2”-13UNC 45 ft-lbs
6” 9/16”-12UNC 57 ft-lbs
8” 5/8”-11UNC 93 ft-lbs
10” 5/8”-11UNC 93 ft-lbs
Occasionally after testing or initial start-up, a minor stem
or packing leak may occur. Adjust the packing plate
bolts in accordance with the section entitled "Valve