KLINGER SCHÖNEBERG INTEC K411-T&L-STD Setup guide

Assembly and Repair Instructions page 1 of 6
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INTEC K411- T&L-ST file:
Montage-Reparatur-
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EN_22012016
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Assembly and Repair Instructions for KLINGER SCHÖNEBERG Ball Valves, Type INTEC K411-T&L-ST
Table of Contents
1
Validity ........................................................................................................................................................... 2
2 General Remarks ........................................................................................................................................... 2
3 Construction and Components INTEC K411-T&L-ST ................................................................................. 3
4 Assembly of the INTEC K411-T&L-ST ........................................................................................................ 4
4.1 Preparing for Assembly ........................................................................................................................ 4
4.2 Assembling the Valve ........................................................................................................................... 4
4.3 Function, Strength and Tightness Test ................................................................................................. 5
4.4 Independent Conversion and Manufacture of Spare Parts ................................................................... 5
4.5 Incorrect Operation ............................................................................................................................... 5
5 ismantling .................................................................................................................................................... 5
5.1 Precautionary Measures....................................................................................................................... 5
5.2 Preparing for ismantling ..................................................................................................................... 6
5.3 ismantling ........................................................................................................................................... 6
5.4 Final Cleaning and Recording of amage ............................................................................................ 6

Assembly and Repair Instructions page 2 of 6
release 0
INTEC K411- T&L-ST file:
Montage-Reparatur-
Anl INTE K411 T&L ST -
EN_22012016
Provide: Hauck Approval: Roth
Printed
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ages will not be updated
ate: 22.01.2016
1Validity
These Assembly and Repair Instructions are applicable to the type series listed below:
INTEC K411-T&L-ST
2General Remarks
These Assembly and Repair Instructions are designed to provide assistance in assembling, servicing and repair-
ing the ball valve INTEC K411-T&L-ST .
The valves may only be dismantled and taken apart by skilled personnel acquainted with the assembly,
commissioning and operation of this product.
Trained personnel within the meaning of these Assembly and Repair Instructions are individuals who are able to
assess the work which they have been entrusted and to recognise possible risks in view of their special training,
their know-how and experience and their knowledge of the pertinent standards.
These instructions as well as the Operating Instructions for KLINGER SCHÖNEBERG Ball Valves must be
observed. KLINGER SCHÖNEBERG GmbH shall no assume no liability for damage or interruptions to operation
arising from incorrect handling or failure to observe these Repair Instructions.

Assembly and Repair Instructions page 3 of 6
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INTEC K411- T&L-ST file:
Montage-Reparatur-
Anl INTE K411 T&L ST -
EN_22012016
Provide: Hauck Approval: Roth
Printed
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ages will not be updated
ate: 22.01.2016
3Construction and Components INTEC K411-T&L-STD
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
part
body
cap
ball
seat
stem
body seal
below seal
upper seal
below cone ring
upper cone ring
below bearing
hex. nut (self- locking)
hex. screw
spring
upper bearing
trunnion bearing
17 trunnion
18
19 seat seal
20 trunnion seal
21 follower ring
22 blind cap
hex. screw

Assembly and Repair Instructions page 4 of 6
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INTEC K411- T&L-ST file:
Montage-Reparatur-
Anl INTE K411 T&L ST -
EN_22012016
Provide: Hauck Approval: Roth
Printed
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ages will not be updated
ate: 22.01.2016
4Assembly of the INTEC K411-T&L-STD
4.1 Preparing for Assembly
All parts must be prepared to assemble the ball valve, i.e. the parts are carefully cleaned and laid on a soft base
(rubber mat or similar).
It must be considered that the plastic parts are almost always soft and very sensitive and that in particular the
sealing surfaces may not be damaged.
4.2 Assembling the Valve
The body (1) of the valve must be tensioned securely and safely in a suitable device; free access to the cavity
and stem must be guaranteed.
Lightly grease the body (1) and the cap (2) and blind cap (22) in the area of the seat ring (4) with high tempera-
ture grease (e.g. Q1) licensed by the F A. Insert spiral spring (16) into cap (2) and blind cap (22). Attention:
quantity of spiral springs according to the specification or resultant torque. Insert follower ring (21), seat seal (19)
and seat ring (4) in cap (2) and blind cap (22). It should be able to insert it with slight manual pressure. If it fits too
tightly or too loosely the dimensions must be checked.
Slightly grease the stem (6) in the area of the below bearing (11) and below seal parts (7) (8) with high tempera-
ture grease licensed by the F A. Similarly slightly grease the body (1) in the area of the bearing and the stem
sealing. Only a light grease film should arise which does not spill out during assembly of the sealing elements.
The grease may be applied with the assistance of a brush for example.
Handle graphite gaskets with more caution because the material breaks easily through strong distortion
In the case of valves stated as being oil- and grease-free the assembly should be made without grease
and without other auxiliary substances.
Thread on bearing (11) and sealing parts (7) (8) to stem (6) and push on stem from the inside through the body
(1). Bearing parts may not be damaged.
Thread on stem sealing parts (9) (10) (12) from the top to the stem (6). Screw on the self-locking nut (14) onto the
stem (8). Tighten nut with wrench.
Tighten the nut up to seated on the sealing package, rotate a ½ turn more, so the sealing package can set. Then
the nut must be rotated a ¼ turn back and after this the torque of the stem has to be tested.
The following table will provide a guide:
N
40/
1
½”
50/ 2
”
80
/
3
”
100
/ 4
”
150
/ 6
”
torque
12
Nm
12
Nm
28 Nm 50 Nm 70 Nm
After testing secure the nut (14) by allen screw.
Fit ball (3) with groove to stem and place in the body.
Coat the trunnion (17) on bearing (13) with high temperature fat (OKS) in order to avoid cold welding.
Slide trunnion seal (20) and bearing (13) on the trunnion (17) and push it into body (1). Tighten Trunnion with hex.
screw (15) in body (1).
on’t shear or damage sealing- and bearing parts.

Assembly and Repair Instructions page 5 of 6
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INTEC K411- T&L-ST file:
Montage-Reparatur-
Anl INTE K411 T&L ST -
EN_22012016
Provide: Hauck Approval: Roth
Printed
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ages will not be updated
ate: 22.01.2016
Insert body seal (5) into body (1). Fit cap (2) and blind cap (22) carefully into body (1) without damaging the body
seal (5). Coat hex. screw (18) on the thread with high temperature fat (OKS) in order to avoid cold welding.
In the case of valves stated as being oil- and grease-free assembly is performed without grease and
without other auxiliary substances.
Tighten hexagon screws (18) crosswise gradually until the seal is evenly pressed out and cap (2) is metallically
on block with body (1).
4.3 Function, Strength and Tightness Test
After assembling the ball valve it must be checked whether it can move freely and whether the ball can turn
unhampered. Finally the ball valve must be subjected to a strength and tightness test in accordance with
EN12266 -1 Nr. P10 / P11 / P12.
4.4 Independent Conversion and Manufacture of Spare Parts
Conversion while changing the valve is only permissible after agreement and written declaration by the manufac-
turer. Original spare parts and accessories authorised by the manufacturer serve the purposes of safety. If other
spare parts are used and consequences result KLINGER SCHÖNEBERG GmbH shall not assume liability.
4.5 Incorrect Operation
The operationally reliability of the valve is only guaranteed if it is used correctly in accordance with the operating
instructions for KLINGER SCHÖNEBERG ball valves. The limit value specified in the technical documentation
may under no circumstances be undercut.
5Dismantling
5.1 Precautionary Measures
In order to ensure that any product residue which has remained in the cavity of the valve cannot lead to risk to the
staff performing the dismantling operation, appropriate protective clothing made of chemical and solvent resistant
material is to be worn on the entire body and a resistant facial protection.
For reasons of caution dismantling should be performed via a catch tank. Any toxic gases or vapours must be ex-
tracted so that they may not reach personnel. This also applies to the final cleaning after dismantling has been
completed.
The ball valves must be brought into a pressure-free state for the purposes of repair. For this purpose they should
be brought into the semi-open position. It will similarly be necessary to perform cleaning on the inside and outside
before dismantling. It is expedient to switch the ball several times during cleaning of the cavity.

Assembly and Repair Instructions page 6 of 6
release 0
INTEC K411- T&L-ST file:
Montage-Reparatur-
Anl INTE K411 T&L ST -
EN_22012016
Provide: Hauck Approval: Roth
Printed
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ages will not be updated
ate: 22.01.2016
5.2 Preparing for ismantling
Before dismantling, the body (1), the cap (2) and the parts of the ball valve should be marked so that the assem-
bly positions can be understood later on.
5.3 ismantling
For the purposes of dismantling the valve is tensioned again securely and safely in a suitable device. Loosening
the hexagonal screws (18) will permit the cap (2) and blind cap (22) to be removed. Move the ball (3) to the open
position (two flat along the flow direction). Press ball (3) into the body (1) with suitable device, to lift the pre-load
from the ball seat (4). Therefore the trunnion can be removed. Remove the device and retain the ball.
After that the stem is dismantled. To unscrew the nut (14) you have to push a wedge into the slit of the nut. Using
a wrench, the nut (14) can be screwed from the stem (6) in anti-clockwise direction. The stem can now be careful-
ly pressed into the ball area. Secure the stem against falling down and damage.
The bearing (11) and below sealing parts (7) (8) can be removed form stem and upper sealing parts (9) (10) (12)
can be removed from the cone.
Then seat ring parts (4) (21) (19) can be dismantled. Finally the body seal (5) is removed. Auxiliary agents will
not usually be required.
5.4 Final Cleaning and Recording of amage
After dismantling all parts are finally cleaned. The dismantled sealing parts are also to be included in cleaning so
that they may be disposed of with problem.
The damage is then recorded.
Special attention must be paid to inside and outside damage to the body parts. The nature of the sealing surfaces
at the ball seal, stem conduit, body sealing and the flange seals must be checked. The body parts are then jet-
cleaned inside and out with glass pearls and cleaned mechanically if necessary and possible. For this purpose
sealing areas must be covered up.
The valves are then to be cleaned anew and are then available for a further visual check for new assembly.
The stem is checked after visual checking for parallel running and traces of pressure of the two other flanges.
Special attention must be directed at the perfect state of the sealing areas. Slight scratches can be removed with
emery cloth. amaged or twisted stems are replaced.
The cleaned ball is firstly visually checked. eep scratches as well as other mechanical damage and chemical
attack on the sealing surface as well as the running surface of the seal ring mean that the ball must be discarded.
Similarly deformation in the area of the ball slit is inadmissible. All screws and sealing parts must be replaced
during every repair.