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Page 3 of 6 The only mechanism of the valve that is adjustable is the stem packing. If adjustment is required the gland bolts may be fastened. Adjustment of the gland bolts should be no more than one-quarter turn at a time. Over tightening will produce high torque and a shortened seal life. MAINTENANCE A repair kit containing two seats, two body seals, one thrust washer and stem packing is available for rebuilding each size and style valve. Be sure to specify size, style, seat and seal materials when ordering. Optional components are also available (ball, stem, handle, etc.). Refer to illustration on last page for part identification and assembly. REBUILDING WARNING- Ball Valves Can Trap Fluids in Ball Cavity When Closed If the valve has been used to control hazardous media, it must be decontaminated before disassembly. It is recommended that the following steps are taken for safe removal and disassembly: -Relieve the line pressure. -Place the valve in half-open position and flush the line to remove any hazardous material from valve. -All persons involved in the removal and disassembly of the valve should wear protective clothing such as face shield, gloves, apron, etc. CAUTION: Exercise caution that sealing and all surfaces are not damaged during disassembly, cleaning or reassembly. 1. Before removing valve from line, rotate ball into the open position. 2. Remove valve from pipeline. Place valve on a clean surface and secure by clamping or bolting. 3. Unscrew the nuts and set aside. Take body and cap apart. 4. Remove body end seal, cap seat and bolts. 5. Rotate ball into the closed position. Remove ball and body seat. 6. If it is necessary to replace stem packing, remove snap ring, handle, stopper, gland bolts and gland. Lower stem into body cavity. Remove stem packing and thrust washer. 7. Clean and inspect all components to be sure they are free from foreign matter and pit marks, paying particular attention to areas that must maintain a seal (the surface against which the seats and body end seal are installed, finished diameter on stem, ball, stem hole). These areas must be free from scratches and pitting. 8. Light marring from the action of the ball against the seats is normal and will not affect the operation. 9. Once all components have been cleaned inspected and replaced as necessary, the valve may be rebuilt with the appropriate factory repair kit. 10. Slide new thrust washer over stem and insert assembly through ball cavity and fully up into stem hole recess. 3

Page 4 of 6 11. Assemble new stem packing and screw the gland. Adjust stem packing to feel firm. DO NOT over-tighten. 12. Install stopper and snap ring. 13. Lightly lubricate ball and seats with a lubricant compatible with the media for which the service is intended. 14. Assemble new seat into body end and install ball into cavity, making sure that portholes are in desired position for operation. Once ball is engaged with stem, rotate to in-line position to prevent ball from falling out during assembly. 15. Insert body end seal on seal surface of body cavity. Install second seat into cap cavity. 16. Screw bolts onto the body. Assemble cap and secure with nuts to the following recommended torque. Item No.:TC-0802A 150# BOLT SIZE RECOMMENDED BOLT TORQUE 5/16" Dia. (1/2”~3/4”) 27 – 33 N-M ( 238.95 – 292.05 Lbf-in) 3/8" Dia. (1”~1 1/4”) 40 – 46 N-M ( 354.00 – 407.10 Lbf-in) 1/2" Dia. (1 1/2”~4”) 100 – 105 N-M ( 885.00 – 929.25 Lbf-in) 5/8" Dia. (5”~8”) 205 – 215 N-M ( 1814.25 – 1902.75 Lbf-in) Item No.:TC-5000/5100 150# BOLT SIZE RECOMMENDED BOLT TORQUE 5/16" Dia. (1/2”~3/4”) 27 – 33 N-M ( 238.95 – 292.05 Lbf-in) 3/8" Dia. (1”~1 1/4”) 40 – 46 N-M ( 354.00 – 407.10 Lbf-in) 1/2" Dia. (1 1/2”~2 1/2”) 100 – 105 N-M ( 885.00 – 929.25 Lbf-in) 5/8" Dia. (3”~6”) 205 – 215 N-M ( 1814.25 – 1902.75 Lbf-in) Item No.:TC-0802A 300# BOLT SIZE RECOMMENDED BOLT TORQUE 3/8" Dia. (1/2”~1 1/4”) 40 – 46 N-M ( 354.00 – 407.10 Lbf-in) 1/2" Dia. (1 1/2”~3”) 100 – 105 N-M ( 885.00 – 929.25 Lbf-in) 5/8" Dia. (4”~5”) 205 – 215 N-M ( 1814.25 – 1902.75 Lbf-in ) 3/4" Dia. (6”) 295 – 305 N-M ( 2610.75 – 2699.25 Lbf-in ) 7/8" Dia. (8”) 500 – 515 N-M (4425.00 – 4557.75 Lbf-in ) 17. Assemble handle and snap ring. 18. Cycle valve open and close to ensure smooth operation. 19. Reinstall into service following the installation procedure. 20. If practical, check leak tightness before reinstalling valve inline. 4