KMC BALL VALVES

User Instructions
◈ Before using this product, please read carefully this User Instructions
for proper use.
◈ Also, always keep this User Instructions in a conspicuous place.

▷ PN 16 ~ PN 40
▷ DN 15 ~ DN 1200
▷ BUTT WELDED & FLANGE END

KMC Corporation
26/BL, INJU INDUSTRIAL COMPLEX,
ASAN CITY, CHUNG-NAM-DO, KOREA
Tel: 82-2-2038-2240/2245 Fax: 82-2-518-2250
Table of contents
1. Product Composition
Product Introduction
Product Description
Name and materials of Each Part
Product Specifications
2. Transportation and Storage
Mark
Transportation
Storage
1) Storage Place
2) Storage Method
Handling
3. Product Installation
Installation Environment
Installation Method
1) Flange type Valve
2) Butt Welding type Valve
3) Burying type Valve
4. Product Operation
Test Operation
Normal Operation
5. Repair and Maintenance
Valve Repair
GEAR Repair
GEAR Setting (In case opening/closure point is not exact)
6. Check
Regular Check
Check at the time of failure occurrence

In the event damage occurred due to the use other than the usage
stated in this User Instructions, we do not assume any
responsibility for such damage.
< The contents of this User Instruction may change
without giving any prior notification. >
KMC CORPORATION
Safety Matters
Read carefully this User Instructions and use the product properly.
Following sign is used to prevent risk toward the user and other
persons, and damage to property, from occurring. This product was
made for the purpose of intercepting a fluid. Be sure to use it after
confirming use and product specifications.

● Following sign indicates uncertain and general uncertain attention, warning

and risk.

This sign indicates the event that risk of the user being killed or
receiving serious wound is foreseeable if the user ignores and wrongly
RISK handles this sign.

This sign indicates the event that risk of the user being killed or
receiving serious wound is foreseeable if the user ignores and wrongly
WARNING handles this sign.

This sign indicates the event that risk of the user being inured or
physical damage occurring is foreseeable.
ATTENTION

● Following sign indicates attention, prohibition/enforcement of an act to

specified risk note.

Indicates there are contents calling attention (including risk,warning).

Detailed attention contents are drawn in the picture.

Indicates prohibition acts. Detailed prohibition contents are drawn in the

picture or nearby location.
 Risk
Do not disassemble, repair or remodel this product at your pleasure.
Explosion and leakage may occur. If this product requires repairing, contact
the head office.

Head office : 26/BL, INJU INDUSTRIAL COMPLEX,

ASAN CITY, CHUNG-NAM-DO, KOREA
Tel: 82-2-2038-2240/2245 Fax: 82-2-518-2250
¾

Warning
Do not keep the valve in an unstable place.
If you keep the valve in an unstable place, the valve may fall resulting in doing
you an injury.

After finishing the installation of the valve, be sure to close the valve.
Improper operation may do damage or injuries to you.

Do not use other fluid than use fluids (water, LNG, LPG).
If other fluid than use fluids is used, the valve may cause failure or explosion.
In the event an accident occurred due to misuse of the user, the responsibility
rests with the user.

Do not use the valve beyond the scope of working temperature and working
pressure. If the valve is used under high temperature and high pressure, it may
cause failure or explosion.

Do not change the structure at the user’s discretion.

Changing the structure may cause fatal damage to the valve.
In the event an accident occurred due to misuse of the user, the responsibility
rests with the user.

Only the person who has a qualification for welding shall perform the
installation of a welding type valve. Perform NDT. In the event an accident
occurred due to welding operation by an unqualified person, the user is
responsible for the accident.

Attention
Do not give excessive force to this valve.
Otherwise, the valve may cause failure, breakage and quality deterioration.

Do not remove the cap before finishing the installation of this valve.
Otherwise, foreign substance may enter the inside of the valve, resulting in
failure or quality deterioration.

Do not mark the body of the valve at the user’s discretion.

Otherwise, it may cause failure, breakage and quality deterioration.

Install the valve after confirming the paint condition of the valve without fail.
In the event the paint peeled off, install the valve after painting enough the
peeled part to prevent corrosion.
Corrosion may cause failure or explosion.
1. Composition
1.1 Introduction

1) KMC BALL VALVE has the following functions including Shut off
function that completely intercepts use fluids.
2) For maintaining the function of this valve continuously, carefully read
this User Instructions and observe following matters without fail
before using the valve.
3) KMC BALL VALVE produces high quality valve according to ISO9000
and designs, manufactures and receive inspection in compliance
with valve-related standards such as ANSI, ASME, API, BS, ISO, MSS,
KGSC etc.

1.2 Product Description

KMC BALL VALVE is composed of SEAT PART that maintains air

tightness and DRIVING PART that returns a ball.
1) The main part of the valve is composed of the pipe whose materials
are same as those of installed pipes and the weight of the valve itself
is light, so that it is easy to install.
2) As all-in-one structure of complete airtight-type, this valve is
manufactured by automatic welding after molding and processing all
assembly parts, so its air tightness became complete resulting in
increased safety of the user and convenience of facilities
maintenance.
3) A bearing was installed in DRIVING PART of the valve, so it became
more convenient to open or close the valve.
1.3 Name and Materials of Each Part < Refer to Figure - 1 >
1) BODY(& End BODY)
: As complete welding type, this is all-in-one structure that
does not allow fluids from leaking at all. This body so constitutes
the outside of the valve, so it protects the valve from outside
impact. After molding the materials into the same steel pipe as
installed pipes, the joint was connected by automatic welding,
resulting in maintaining complete air tightness.

2) BALL
: As the core part of the valve, this ball is a lightweight hollow
type and has excellent air tightness due to its plotting structure.
The materials of the ball is stainless steel(STS304) having
excellent corrosion resistance, so its life span is semi-permanent.

3) SEAT RING
: This plays a role to intercept use fluids by contacting balls
within the valve. It minimizes driving force of the valve and
maintains air tightness by adding reinforced Teflon with which
graphite(GRAPHATE, 25%) was mixed to Teflon(PTFE) that has
excellent resistance to impurities and chemicals and superior
self-lubricities nature.

4) CUP SPRING
: This valve, as plotting structure, maintains air tightness by
giving pressure to SEAT RING in order to smoothly intercept use
fluids under the pressure lower than working pressure and its
materials is composed of spring steel(SK5M).

5) SUPPORT RING
: This wraps SEAT RING and help the valve maintain air
tightness and durability by evenly conveying the force of the
spring and thus sticking to the ball and SEAT RING.

6) DRIVING PART
: DRIVING PART is composed of STEM connected to the ball
and NECK that protects the STEM from the outside. This
minimizes driving torque by installing O-Ring(FPM) and dry
bearing for the purpose of preventing the internal pressure of the
valve from leaking.
 1.4 Product Specifications
1) Specifications Table
Valve Size DN25 DN32 DN40 DN50 DN65 DN80
Pressure Degree(PN) 16 25 16 25 16 25 16 25 16 25 16 25
Working Pressure(bar) 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6
Working Temperature -20℃ ~ 200℃
Use Fluids WATER, LNG, LPG
Connection Method Butt Weld End or FLANGE End
Weight BW 0.9 0.9 1.1 1.1 2.0 2.0 3.5 3.5 4.0 4.0 5.0 5.0
(kg) FLANGE 3.4 3.7 4.7 5.2 6.2 6.7 9.3 9.9 11.3 12.6 14.5 16.8
Valve Size DN100 DN125 DN150 DN200 DN250 DN300
Pressure Degree(PN) 16 25 16 25 16 25 16 25 16 25 16 25
Working Pressure(bar) 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6
Working Temperature -20℃ ~ 200℃
Use Fluids WATER, LNG, LPG
Connection Method Butt Weld End or FLANGE End
Weight BW 20 31 31 29 29 68 68 122 122 370 370
(kg) FLANGE 30 48 53 51 58 101 118 172 189 410 460
Valve Size DN350 DN400 DN450 DN500 DN550 DN600
Pressure Degree(PN) 16 25 16 25 16 25 16 25 16 25 16 25
Working Pressure(bar) 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6
Working Temperature -20℃ ~ 200℃
Use Fluids WATER, LNG, LPG
Connection Method Butt Weld End or FLANGE End
Weight BW 440 440 640 640 820 820 1190 1190 1300 1300 1480 1480
(kg) FLANGE 480 560 710 860 950 1010 1290 1440 1420 1590 1570 1750
Valve Size DN650 DN700 DN750 DN800 DN850 DN900
Pressure Degree(PN) 16 25 16 25 16 25 16 25 16 25 16 25
Working Pressure(bar) 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6 11 17.6
Working Temperature -20℃ ~ 200℃
Use Fluids WATER, LNG, LPG
Connection Method Butt Weld End or FLANGE End
Weight BW 1630 1630 1800 1800 1980 1980 2180 2180 2480 2480 3270 3270
(kg) FLANGE 1730 1930 1910 1750 2180 2350 2330 2590 2710 2820 3540 3770
Valve Size DN1000 DN1200
Pressure Degree(PN) 16 25 16 25
Working Pressure(bar) 11 17.6 11 17.6
Working Temperature -20℃ ~ 200℃
Use Fluids WATER, LNG, LPG
Connection Method Butt Weld End or FLANGE End
Weight BW 6400 6400 8400 8400
(kg) FLANGE 7000 7400 9300 9700
 2) DIMENSION
A. HANDLE TYPE(DN25 ~ DN150)

P
N

D J

H
G
C
B

AL1
L2

J (n-
Division PN ФA ФB ФC D L1 L2 N P ФG ФH
Ф)
DN25 16 20 33.7 48.6 51 230 160 157.5 M12 115 85 4-Ф14

DN32 16 25 42.4 60.5 49 260 180 157.5 M12 140 100 4-Ф18

DN40 16 32 48.3 76.3 57 260 200 230 M16 150 110 4-Ф18

DN50 16 40 60.3 89.1 55.5 300 230 230 M16 165 125 4-Ф18

DN65 16 50 76.1 114.3 104 300 270 300 4K-16 185 145 8-Ф18

DN80 16 65 88.9 139.8 100 300 280 300 4K-16 200 160 8-Ф18

DN100 16 80 114.3 165.2 148 325 305 400 4K-20 220 180 8-Ф18

DN125 16 100 141.3 216.3 145.5 325 356 450 4K-20 250 210 8-Ф18

DN150 16 125 168.3 219.1 146 350 394 450 4K-20 285 240 8-Ф22

DN25 25 20 33.7 48.6 51 230 160 157.5 M12 115 85 4-Ф14

DN32 25 25 42.4 60.5 49 260 180 157.5 M12 140 100 4-Ф18

DN40 25 32 48.3 76.3 57 260 200 230 M16 150 110 4-Ф18

DN50 25 40 60.3 89.1 55.5 300 230 230 M16 165 120 4-Ф18

DN65 25 50 76.1 114.3 104 300 270 300 4K-16 185 145 8-Ф18

DN80 25 65 88.9 139.8 100 300 280 300 4K-16 200 160 8-Ф18

DN100 25 100 114.3 165.2 148 325 305 400 4K-20 235 190 8-Ф22

DN125 25 125 141.3 216.3 145.5 325 381 450 4K-20 270 220 8-Ф26

DN150 25 150 168.3 219.1 146 350 403 450 4K-20 300 250 8-Ф26
 O R
P
M

Q
B. GEAR TYPE(DN 200 ~ DN 1200)

N
E
D

F
H
G
C
B

A
J
L1
L2

DN300 16 248.5 326.9 457.2 102.7 80 635 630 404 272 500 460 410 12-Ф26
DN350 16 300 355.6 508 172 100 650 690 489 331.4 600 520 470 16-Ф26

DN400 16 337 406.4 558.8 159.6 100 760 762 507 360.5 700 580 525 16-Ф30

DN450 16 337 457 558.8 159.6 100 842 860 507 360.5 700 640 585 20-Ф30

DN500 16 387 508 660 139.5 123 910 914 540 360.5 700 715 650 20-Ф33
DN550 16 438 558.8 718 145.5 133 1092 1092 574.5 360.5 700 749.3 692.2 20-Ф35

DN600 16 489 609.6 812.8 173.6 150 1065 1067 662 413.4 800 840 770 20-Ф36

DN650 16 546 660.4 898 221 150 1245 1245 749 413.4 800 870 806.5 24-Ф35.1

DN700 16 591 711.2 1016 189.5 150 1346 1346 798 540 900 910 840 24-Ф36

DN750 16 635 762 1020 231.5 180 1397 1397 838.3 540 900 984.3 914.4 28-Ф35.1
DN800 16 686 812.8 1095 219.5 180 1524 1524 863.8 540 900 1025 950 24-Ф39

DN850 16 737 863.6 1172 206.5 180 1625 1625 889.3 540 900 1111.2 1028.8 32-Ф41.1

DN900 16 781 914.4 1237 201.5 180 1727 1727 916.8 540 900 1125 1050 28-Ф39

DN1000 16 920 1020 1415 237.5 180 1750 1750 1060 790 900 1238.3 1143 32-Ф42
DN1200 16 1026 1220 1576 198.5 185 2050 2050 1132.5 790 900 1466.9 1371.6 32-Ф50

DN200 25 150 219.1 267.4 120.5 57 400 550 304.2 243.6 400 360 310 12-Ф26

DN250 25 200.8 273.1 355.6 120 67 560 650 350.8 252 500 425 370 12-Ф30

DN300 25 248.5 323.9 457.2 102.7 80 635 630 404 272 500 485 430 12-Ф30
DN350 25 300 355.6 508 172 100 650 690 489 331.4 600 555 490 16-Ф33

DN400 25 337 406.4 558.8 159.6 100 760 762 507 360.5 700 620 550 16-Ф36

DN450 25 337 457 558.8 159.6 100 842 860 507 360.5 700 670 600 20-Ф36

DN500 25 387 508 660 139.5 123 910 914 540 360.5 700 730 660 20-Ф36

DN550 25 438 558.8 718 145.5 133 1092 1092 574.5 360.5 700 838.2 743 24-Ф41.2
DN600 25 489 609.6 812.8 173.6 150 1065 1067 662 413.4 800 845 770 20-Ф39

DN650 25 546 660.4 898 221 150 1245 1245 749 413.4 800 971.6 876.4 28-Ф44.5

DN700 25 591 711.2 1016 189.5 150 1346 1346 798 540 900 960 875 24-Ф42

DN750 25 635 762 1020 231.5 180 1397 1397 838.3 540 900 1092.2 997 28-Ф47.8
DN800 25 686 812.8 1095 219.5 180 1524 1524 863.8 540 900 1090 990 24-Ф42

DN850 25 737 863.6 1172 206.5 180 1625 1625 889.3 540 900 1092.2 997 24-Ф48

DN900 25 781 914.4 1237 201.5 180 1727 1727 916.8 540 900 1185 1090 28-Ф48

DN1000 25 920 1020 1415 237.5 180 1750 1750 1060 790 900 1238.3 1143 32-Ф42
DN1200 25 1026 1220 1576 198.5 185 2050 2050 1132.5 790 900 1466.9 1371.6 32-Ф50
C. NECK FLANGE(GEAR TYPE)

Division PN O P Q R BCD BOLT GEAR

DN200 175 33.3 10x8 4-Ф17 140 M16x40L 01-1

DN250 210 43.3 12x8 4-Ф21 165 M20x40L 02-1

DN300 210 53.8 14x9 4-Ф21 165 M20x45L 02-1

DN350 240 69.9 20x12 8-Ф17 205 M16x50L 03-1

DN400
69.9 20x12
DN450
300 8-Ф17 254 M16x50L 04-1
DN500
85.4 22x14
DN550 16

DN600 112.8
350 28x16(2) 8-Ф21 298 M20x55L 05-1
DN650 116.4

DN700

DN750 350 124.8 32x18(2) 8-Ф21 298 M30x70L 06-1

DN800

DN1000 475 168 22x40(2) 8-Ф37 406 M36x80L 07-1

DN1200 560 178 22x40(2) 12-Ф37 483 M36x90L 09-1

DN200 175 33.3 10x8 4-Ф17 140 M16x40L 01-1

DN250 210 43.3 12x8 4-Ф21 165 M20x40L 02-1

DN300 210 53.8 14x9 4-Ф21 165 M20x45L 02-1

DN350 240 69.9 20x12 8-Ф17 205 M16x50L 03-1

DN400
69.9 20x12
DN450
300 8-Ф17 254 M16x50L 04-1
DN500
85.4 22x14
DN550

DN600 25
112.8
DN650
350 28x16(2) 8-Ф21 298 M20x55L 05-1
DN700
116.4
DN750

DN800

DN850 415 124 32x18(2) 8-Ф31 356 M30x80L 06-1

DN900

DN1000 475 168 22x40(2) 8-Ф37 406 M36x80L 07-1

DN1200 560 178 22x40(2) 12-Ф37 483 M36x90L 09-1

 2. Transportation and Storage
Transport and load the valve with the valve properly packed.
In case the valve is unpacked for dimension inspection etc., pack the valve
ATTENTION
again in its original state to store when the inspection has been
finished. Otherwise, it may cause quality deterioration and failure due to
various causes including moisture, dust and vibration.

Store the valve in a flat and steady place.

Otherwise, it may fall or come down due to vibration or impact resulting in

ATTENTION doing injuries to the user.

Do not remove a protection cap before installing this valve.

Otherwise, dust or other impurities may enter the inside of the valve,
ATTENTION causing failure or quality deterioration.

Do not use the handle of the valve as a transportation tool.

Otherwise, failure or quality deterioration may occur due to excessive force.
ATTENTION

2.1 Mark
A. There is a least identification mark(marking, label) on both sides of
the packing box(wooden, paper) of the valve, so confirm such mark
before using the valve.
B. Marks include a customer name, destination, a product name and
specifications etc.
2.2 Storage
1) Keep the valve so that risk of damaging it may be minimized and its
maintenance may be convenient, and handle it in a safe and proper
way.
 2) When loading it during storage, load it properly by using a support or
a box so that the product may not change and may support total
weight.
3) Keep the valve in the place far from harmful chemicals, paint, solvent
and harmful materials.
4) Handle properly all products, do not open the box unnecessarily, and
arrange all products so as to easily identify each of them.
2.3 Storage Place
1) Storage place shall be always kept clean, free of dust, soil or
impurities.
2) No inflammables or other things shall be kept in the storage place
that may have harmful effect on the product.
3) To minimize the pollution and mechanical damage of the product, it
is necessary to maintain indoor facilities in the storage place or to
take some measures so that a mouse or other animals may not enter
the storage place.
4) When keeping the product outdoor, install a cover to protect the
product from snow or rain, and keep it in the well-ventilated place so
as to reduce effect by heat.
5) When keeping the product outdoor, the materials of the cover shall
have excellent moisture and wind-resistance.
6) When keeping the product outdoor, the product shall be kept in the
dry place.
7) When keeping the product outdoor, carefully check it at least once
every three months to see identification number, marking, a
protective cover, sealing up condition, painting and corrosion
condition, whether or not physical damage occurred and cleaning
condition etc.
2.4 Notes when handling the product
1) Protect appropriately the product by using a palette or a box and
handle it safely by using a pork lift or crane etc. in order to prevent
damage or deterioration due to causes such as impact or corrosion
etc. which may occur in the place where the product is kept and a
product warehouse while handling and keeping it.
2) Take appropriate measures for preventing damage while handling the
product so that the processing surface and identification mark of the
valve may not be worn, got hacked, polluted or damaged due to
carelessness.
3) When moving the valve, use appropriate exclusive-use equipment
such as a pork lift so as not to overturn it. Especially, careful
attention must be paid when lifting or lowering a large or medium-
sized valve.

2.5 Notes when moving the product

1) Hold the packing condition as same as the first when moving the
product.
2) When moving the valve, use exclusive-use equipment such as a pork
lift and a crane etc.
3) Do not use the handle and conduct operation so that the body of the
valve may be directly hung when lifting or lowering the valve,
4) When loading the valve, lay mats on the bottom of the loading deck
so that the valve may be laid on such mats, and see that the body of
the valve may not contact the metal part of the loading deck, and
fasten tightly the valves so that each valve do not collide with each
other.
5) When loading the valve, be sure to load the valve with it laid down
and firmly support the valve by using a support and a rope so that it
may not roll or move.
6) Strongly push the valve forward to the loading deck and firmly stick it
to a car-body using a rope etc. in order to prevent it from being
overturned during transportation.
7) Handle with care so that the valve may not become dirty due to
impurities.
8) Transport the valve with care because the transport under the
condition of holding the handle of the valve may affect the
performance of the product.
9) Take account of the natural features of where a vehicle is to stop,
and, especially, in the case of slant an incline, careful attention must
be paid.
10) Avoid an uneven road while transporting the valve, and where
required by circumstances, drive a vehicle after confirming the
loading condition.
11) After you drove a vehicle on the uneven road, stop temporarily and
ascertain whether or not the loading condition is good and the valve
was loosened.
 3. Product Installation
3.1 Installation Environment
A ball valve has excellent interception function but the function may
decline due to impurities and impact, so careful attention must be paid
in handling and controlling this ball valve.
For maintaining the function of KMC ball valve for long-term period, you
are required to comply with following details.

Only the person who has a qualification for welding must install a welding
type valve and perform NDT. In the event an accident occurred due to
WARNING welding operation by an unqualified person, the responsibility rests with the
user.

Install after confirming working temperature(-20℃~200℃) and working

pressure (PN16, PN40) of the valve. Avoid the place where temporary high
ATTENTION temperature and high pressure is foreseeable, or, where required by
circumstances, separately install safety devices (gauge, safety valve etc.)
to use the valve.

When installing the valve, select steady place where there is no vibration
and oil and temperature change is small.
ATTENTION

Install the valve in the place where ground sinking is not foreseeable. When
installing the valve in the place where the ground is soft, conduct
ATTENTION installation after making the ground hard by using sand or pebble so that
the ground may not sink.

Secure enough space to install the valve in order to protect you from the
risk of injuries when installing and operating the valve. (Refer to Table 3.1
and 3.2).
ATTENTION

When the installation of the valve has been finished, be sure to close the
valve without fail. Misuse may cause damage or injuries to you.
ATTENTION
Table 3.1 External Dimension Table of Flange type Valve
▣ DN 25~DN150 ▣ DN200~DN1200
A A
C C

B
B

E
E

D D
Table 3.2 External Dimension Table of Welding type Valve
▣ DN25~DN150 ▣ DN200~DN1200
A
A C
C

B
B

E
E

D
D
 3.2 Installation Method

1) Installing Flange type Valve

Do not remove the protective cap before installing this valve. Otherwise,
dust or impurities may enter the inside of the valve and cause failure or
ATTENTION
quality deterioration.

When tightening a volt and a nut, give force evenly in the diagonal
direction. Otherwise, it may badly affect pipes and valves.

ATTENTION
① Remove the protective cap attached to both ends of
the valve. Check and see whether or not the valve is open. If it
is closed, open it by using the handle of the valve.

② Make alignment so that the direction coincides with that of the

pipe to which the valve is connected.

③ After inserting a gasket that meets the specifications of the

flange, tighten the bolt and nut that meet the specifications. Be
careful in using a gasket (insulated, general). Leakage must not
occur after the bolt being tightened in the diagonal direction.
 ④ When tightening a bolt and a nut, use tools suitable to
specifications.
After installation, conduct air tightness and pressure-resisting
test before you use it.

2) Installing Butt Welding Valve

Do not remove the protective cap before installing this valve.

Otherwise, dust or other impurities may enter the inside of the valve and
cause failure or quality deterioration.
ATTENTION
Remove completely impurities harmful to welding operation such as rust, oil,
paint, sand and moisture etc. of the surface of the valve and a pipe.
Otherwise, impurities may cause problems in welding operation.
ATTENTION
Only the person who has a qualification for welding must install a welding
type valve and perform NDT. In the event an accident occurred due to
welding operation by an unqualified person, the responsibility rests with the
ATTENTION user.

① Remove the protective cap attached to both ends of the valve.

At that time, check and see whether or not the valve is opened.
If it is closed, be sure to open it by using the handle of the valve.

② Make alignment so that the direction may coincide with that of

the pipe to which it is connected.

③ Check and see the joint between the valve and a pipe through
non-destructive inspection etc.
☞ Observe beveling angle of both ends of the pipe to be connected to the valve.
Be sure to cool the welding part slowly.
Fast cooling may occur serious problems on the side of the welding part.
☞ If a crack or an air bubble occurs on the welding part, removes such part
enough before performing welding operation.

④ The valve shall be completely open when welded into horizontal piping
(Fig. 6-1 & 6-2). When welding the valve into vertical piping, the valve shall be
open when the upper seam is welded (Fig. 6-3). If the valve is closed when the
upper seam is welded, it must be filled with water (Fig. 6-4). IN gas welding the
valve shall be closed when welding the bottom seam (Fig. 6-5)

⑤ Welding method when doing extra job for stem extension

- Check whether the direction of line on the upper stem is parallel to the
pipe
- Do 4 point track weld the Part “A” as the picture below.

-Weld Part “A”, taking 4 steps like the following pictures.

- Valve size below DN65 is to be put into water for cooling off
after welding is finished.
- The suitable water temperature is 10~15℃
- Valve size above DN80 can be cooled off in the air after welding is done.

⑥ The feasible directions to install hand levers.

⑦ The feasible directions to install gears or actuators.

⑧ The feasible directions to install underground valves.

⑨ The examples of incorrect installations.

 3) Notes when burying this valve
In the event installing this valve underground, comply with following notes
for safe installation.
Install in the same way as above-mentioned 1) and 2).
ATTENTION
When burying the valve, install it in the place where ground sinking is not
foreseeable.
When installing the valve in the place where the ground is soft, make the
ATTENTION ground hard by using sand or pebble etc. before installation so that the
ground may not sink.

Install the valve after checking the painting condition of the valve without
fail.
In the event the paint peeled off from the surface of the valve, enough
ATTENTION
paint the peeled part so as to prevent corrosion before installation.
Corrosion may cause failure or explosion.

After burying the valve, be sure to mark the ground for confirming
installation location. Protect the valve from subsequent excavation works

ATTENTION such as water supply works or electric works.

Secure installation enough space so that installation and operation work

are easy and the risk of doing injuries to the user may be reduced.
ATTENTION

Be sure to install appropriate safety devices (manometer, safety valve etc.)

at the front and back side of the valve in the place where pressure more
ATTENTION than working pressure is foreseeable.
 4. Operation
4.1 Test Operation
Check and see installation conditions such as working pressure and
working temperature of the valve.
If the pressure and temperature is higher than the specifications of the
ATTENTION valve, stop it from operating and replace the valve or supplement an

appropriate device such as a safety valve etc.

Check and see whether or not the valve is intercepted before providing
working pressure.
If the valve is opened, be sure to intercept it without fail.
ATTENTION

Exactly check the opening/closure direction of the valve and do not

conduct excessive operation.
At the time of opening, turn the handle round clockwise and at the time of
ATTENTION closure, turn the handle counterclockwise (Handle type 90°, GEAR type 34
revolution).

1) Check and see the opening/closure condition(3,4 times) of the ball

by turning round the hand wheel, opening/closure device, by 90°
under the condition(0 bar) in which no pressure is applied.
2) Check and see whether or not there is any problem in the body,
welding joint, surface painting, label etc. under the condition(0 bar)
in which no pressure is applied.
3) Be sure to check and see working pressure. If the pressure is high,
replace the valve or install a safety device.
4) Check and se whether or not there is any problem in
opening/closure under the condition in which working pressure is
applied.
5) Check and see whether or not there is any leakage in the body,
welding joint and neck part etc. under the condition in which
working pressure is applied.
6) In the event there is no problem at the time of test operation,
intercept the valve.
7) Do not give excessive force at the time of opening and closing the
valve.
8) Check the valve regularly for safe long-term use of it.
9) If leakage occurs in the body of the valve, replace or repair the
valve, and if leakage occurs in a connection part, be sure to
intercept pressure source and then removes the pressure before
remedying and supplementing the leakage part.
 4.2 Normal Operation

If the valve is not used for a long-term period, sticking phenomenon may
occur between the ball and SEAT RING, so when you use it after have left
it unused for a long time, operate it slowly and then race it more than 3 or
ATTENTION
4 times.

If working pressure rises high in a moment, install by all means a safety

device (manometer, safety valve) in the front and back of the valve to
ATTENTION protect it.

1) Before applying working pressure, check and see connection

condition of the valve, painting condition of the body, and whether
or not there is any deformation and label was attached. If you
found any problem, be sure to repair it.
2) Before applying working pressure, check and see opening/closure
condition by turning the handle 3,4 times.
3) If you found no problem, apply working pressure after setting the
valve to interception location. At that time, use fluids apply
pressure up to the front of the valve, be sure to check and see
whether or not any problem(leakage, deformation) occurred in the
part connected to the body of the valve.
4) If you found no problem occurred, turn the handle round
counterclockwise to let fluids pass. At that time, check and see
whether or not any problem occurred in the part connected to the
body of the valve and the neck part.
5) When you want to intercept the valve, turn the handle round
counterclockwise.
6) When conducting opening/closure operation of the valve, do not
operate it excessively.
7) Check the valve regularly for safe and long-term use.
8) If there is any leak in the body of the valve replace or repair it. If
any leak occurs in a connection part, be sure to intercept pressure
source and remove pressure to repair or supplement the leak part.
5. Maintenance
5.1 Maintenance of the valve
Refer to this description when any problem occurred in the neck part of the
valve.
When any problem occurred in other part than above-mentioned one, refer
to ’6.2 Inspection at the time of failure occurrence’.

1) Disassembling and assembling HANDLE TYPE NECK PART

(DN25, DN32, DN40, DN50, DN65, DN150)

▷ Disassembling order
① Remove SOCKET SCREW
② Remove HANDLE
③ Remove STOPPER PIN
④ Remove BACK UP RING
⑤ Remove THRUST RING 1
⑥ Remove O-RING

▷ At the time of disassembly and assembly, take notice of following points.

① Check whether or not O-RING was damaged or deformed
: Replace it with new one of same specifications
② Check whether or not THRUST RING was damaged or deformed
: Replace it with new one of same specifications
③ Check whether or not STOPPER PIN was damaged or deformed
: Replace it with new one of same specifications
④ Check whether or not impurities entered : Remove impurities

▷ When assembling this part, perform in the reverse order of disassembling

order taking notice for impurities not to enter.
Insert O-RING → Insert THRUST RING1 → Insert BACK UP RING →Insert
STOPPER PIN (STEM) → Insert HANDLE → Tighten SOCKET SCREW
 2) Disassembling and assembling GEAR TYPE NECK PART
(DN200~DN900)
▷ Disassembling order
① Remove BOLT for clamping GEAR
② Remove GEAR
③ Remove KEY
④ Remove SNAP RING
⑤ Remove BACK UP RING
⑥ Remove THRUST RING 1
⑦ Remove O-RING

▷ Take notice of following points at the time of disassembly and assembly.

① Check whether or not O-RING was damaged or deformed
: Replace it with new one of same specifications
② Check whether or not THRUST RING was damaged or deformed
: Replace it with new one of same specifications
③ Check whether or not STOPPER PIN was damaged or deformed
: Replace it with new one of same specifications
④ Check whether or not impurities entered : Remove impurities
▷ When assembling this part, perform in the reverse order of disassembling
order taking notice for impurities not to enter.
Insert O-RING → Insert THRUST RING1 → Tighten BACK UP RING →
Tighten SNAP RING → lock KEY → Tighten GEAR → Tighten clamping
BOLT
 5.2 Method to set GEAR and notes(Applied to only more than DN 300)
1) Method to set GEAR

GREASE
INDICATOR
NIPPLE
GEAR
BODY
LOCK NUT HAND WHEEL

A
B

▣ Open Direction Setting

① Check and see whether or not the OPEN direction of GEAR and the valve
coincides.
Check and see whether or not the indication line of the upper part of the
valve stem coincides with the OPEN direction.
② Make setting by adjusting bolt A.

If less opened : Turn the bolt round clockwise.

If more opened : Turn the bolt round counterclockwise.

③ After tightening bolt A until you feel as if the bolt contacts the wall, and
tighten firmly a clamping nut.

▣ Closed Direction Setting

① Check and see whether or not the indication hand direction of GEAR
coincides with CLOSE(90°) direction. Check and see whether or not the
indication line of the upper part of the valve stem coincides with
CLOSE(90°) of GEAR.
② Make setting by adjusting bolt B.

If less closed : Turn the bolt round clockwise.

 If more closed : Turn the bolt round counterclockwise.
③ After tightening bolt B, tighten firmly a clamping nut.
When GEAR revolves, some play occurs due to processing and assembly
of GEAR, which does not indicate any defect in the function of the product.

ATTENTION Use this without anxiety.

Turn GEAR round by about 1/2~1 revolutions in the reverse direction

before and after opening/closure. Then the force applied to GEAR tooth
ATTENTION
disappears, extending the life span of GEAR.

Reference GEAR Installation Specifications Table

45°

A
S

4-N
BCD Q
Unit : mm
DN400 DN500 DN750~
Valve Specifications DN200 DN250 DN300 DN350 DN600 DN650 DN700
DN450 DN550 DN900
Gear Number 01-1 02-1 03-1 04-1 05-1 06-1
Flange Number F-14 F-16 F-25 F-30 F-35
Stem hole ФA 30 42 50 65 80 100 110 120
Key S 10x8 12x8 14x9 20x12 22x14 28x16(2) 32x18(2)
Specifications T 33.3 45.8 53.8 69.9 85.4 106.4 116.4 117.4 127.4
Tap 4-M16 4-M20
N 8-M16-Dp25 8-M20-Dp25 8-M30-Dp30
specifications -Dp20 -Dp20
BCD Q 140 165 205 254 298 356
Valve Specifications DN1000 DN1200

Gear Number 07-1 09-1

Flange Number F-40 F-48
Stem hole ФA 150 160
Key S 22x40 22x40
Specifications T 168 178
Tap 8-M36 4-M20
N
specifications -Dp52 -Dp20
BCD Q 406 483
5.3 Disassembling and assembling GEAR

Use this disassembling and assembling method only when regularly

exchanging grease.
Unnecessary disassembly operation has an effect on the quality of GEAR and the
valve.

▷ Disassembling Order
① Remove INDICATOR clamping BOLT 1
② Remove INDISCTOR
③ Remove GEAR COVER clamping BOLT 2
④ Remove GEAR COVER
▷ When disassembling and assembling GEAR, comply with following matters.
① Check and see whether or not GEAR was damaged or deformed : Replace
GEAR when it was destroyed.
② Check and see whether or not impurities entered : Remove impurities
▷ When assembling GEAR, perform in the reverse order of a disassembly method
taking note for impurities not to enter.
Place GEAR COVER → Tighten GEAR COVER clamping BOLT 2 → Clamp
INDISCTOR → Tighten INDICATOR clamping BOLT 1
6. Check

6.1 Regular check

Check Item Matters to be enforced
Check Valve Execution of racing once per quarter(2~3 revolutions
Torque per one time)
In case paint peeled off, execution of paint operation
Check Valve
after removing the relevant part. Removal of
Condition
impurities in STOPPER part.
In accordance with regular check day.
Check Leak The body of the valve, welding connection part, valve
stem part
In case paint peeled off, execution of paint operation
Check GEAR
after removing the relevant part.
Condition
Whether or not times of racing increased
Check GEAR Exchange period : More than one time per two years
Grease Supplement period : More than one time per year

6.2 Items to be checked at the time of failure occurrence

Items to be
Type Actions to be Taken
Checked

A. In case of more than 30kg.m,

replace GEAR or the valve
Check Torque
B. In case of less than 30kg.m,
Opening/Closure conduct opening/closure operation
is Difficult. several times
A. In case of breakage, replace GEAR
Check GEAR
Condition
B. Exchange and repair grease
Check the Body In case of crack and pin hole
of the Valve occurrence, replace the valve
In case of gasket breakage, replace it
Leak Occurs.
with new one of same pacifications
Check Flange
Tightens the bolt and nut.
 In case of O-RING breakage, replace it
Check STEM part
with new one of same specifications
Check whether or If there is any impurities, removes
not impurities impurities
exists in If there is no impurities, replace the
STOPPER part valve
A. In case location is improper
1) In case of GEAR type, reset
Check the
Problems in opening/closure point
location of
2) In case of handle type, replace
intercepting INDICATION
the valve
fluids HAND
B. In case location is exact, replace
the valve

In case GEAR races, replace GEAR.

Check ball driving
In case of large play, replace the valve

* If this valve doesn’t work, contact the head office for A/S.
* When you request A/S, please let us know the details stated in the upper
part of the valve, and present condition.
* Where to contact for technical consultation and A/S

KMC Corporation
26/BL, INJU INDUSTRIAL COMPLEX,
ASAN CITY, CHUNG-NAM-DO, KOREA
Tel: 82-2-2038-2240/2245 Fax: 82-2-518-2250