Swagelok SK Series Operating instructions

Swagelok®SK Series Ball Valve
Service Instructions
Tools Required
Part Tool Size
Valve body
Bench vise —
Open-end wrench 1 5/16 in.
Panel Nut Open-end wrench 1 in.
End screw
Open-end wrench 3/4 in.
Crow's foot 3/4 in.
Socket 3/4 in.
Packing bolt Socket 3/8 in.
Packing bolt,
end screw Torque wrench
Capable of
600 in.·lb (67.8 N·m,
691 cm·kg)
Gland Pick —
Handle Hex Key 3/32 in.
Seat Seal Kit Contents
Seat backup
ring (4)
Seat spring (2) Seat O-ring (2)
Lubricant with MSDS
Seat (2) End screw
gasket (2) Gland
assembly tool
Symbol
Discard
Stem and Seat Seal Kit - includes Seat Seal Kit contents and the following:
Stem thrust
washer
Stem backup
ring
Chamfered
backup ring
Stem O-ring Packing bolt
gasket

2
Exploded View
Handle
Packing bolt
Packing bolt gasket
Stem thrust washer
Chamfered backup ring
Stem backup ring
Stem O-ring
Stem
Panel nut
Valve body
End screw (2)
Seat spring (2)
Seat gland (2)
Seat (2)
End screw gasket (2)
Ball
Seat
O-ring
(2)
Seat
backup ring
(4)
Set screw
Stem Seal Maintenance
Seat Seal Maintenance

3
Reassembly
6. Wipe seat gland and end screw clean with a lint-free
cloth.
7. Insert seat spring into the end screw. Either
orientation for the spring is acceptable.
8. Lubricate seat O-ring. Place seat backup rings and
seat O-ring on seat gland.
9. Place the gland assembly tool over the end screw
and push the seat gland assembly into the end
screw.
10. Lubricate the top and bottom surfaces of the seat
and place in end screw, bottom surface first.
11. Place the end screw gasket onto the sealing
surface of the end screw.
12. Push down on the stem to retain the ball with the
valve in the open position.
End screw
Gland assembly tool
Seat gland assembly
WARNING
Before removing a valve from the system for
service, you must
• depressurize system
• cycle the valve
WARNING
Residual system media may be left in the
valve.
Seat Seal Maintenance
Disassembly
1. Remove the valve from the system. Place the valve in
the open position to retain ball.
2. Loosen the handle set screw using a hex key and
remove the handle.
3. Place valve in a vise or 15/16 in. wrench.
4. Press down on the stem to retain the ball and remove
one end screw assembly.
Complete the maintenance on one end screw
assembly before proceeding to the other end screw
assembly.
5. Use a pick or similar tool to remove parts from the
end screw as shown. Set seat gland and end screw
on a clean surface.
CAUTION
Do not to scratch the seat gland. Leakage
could result.
Top surface
Bottom surface
End screw
End screw gasket
Sealing surface
Seat O-ring Seat gland
Seat backup ring
Seat backup ring
CAUTION
All parts must be kept clean and lint-free.
Contamination of the parts will cause
leakage.
Seat gland
Seat backup ring Seat O-ring
Seat backup ring
End screw
End screw
gasket
Seat
Seat spring
End screw assembly
Handle

4
13. Remove valve assembly from vise and hold with the
open end facing downward.
14. Ensure the end screw gasket is resting on the
sealing surface of the end screw. Orient the end
screw assembly as shown and screw into the valve
assembly until no threads are visible.
15. Place the valve assembly into the vise. Torque the end
screw to 300 to 350 in.·lb (33.9 to 39.5 N·m, 345 to
403 cm·kg).
NOTICE
Ensure end screw gasket remains on sealing
surface or damage to the gasket could result.
Note: If also performing stem seal maintenance, proceed
to Stem Seal Maintenance, Disassembly.
16. Repeat steps 4 through 15 for the other end screw
assembly.
17. Place the handle on the valve stem, aligning the larger
stem flat and set screw hole, with the set screw hole
opposite the logo side of the valve. Tighten set screw
with a hex key.
18. Test the fully assembled valve for proper operation
and leak-tight integrity.
Stem Seal Maintenance
Note: Whenever removing the valve from the system and
not performing seat seal maintenance, secure the
end screw using a 3/4 in. wrench when loosening
the end fitting in order to preserve the end screw
seal.
Disassembly
1. Loosen the handle set screw using a hex key.
2. Remove the handle, packing bolt/stem assembly,
and the packing bolt gasket from the valve body.
3. Remove one end screw assembly and set on a clean
surface.
Note: If also performing seat seal maintenance,
remove the end screw not removed and
replaced during Seat Seal Maintenance.
4. Remove the stem assembly from the packing bolt
and set on a clean surface.
5. Remove parts shown using a pick or similar tool.
CAUTION
Do not to scratch the stem. Leakage could
result.
Stem O-ring
Stem backup ring
Chamfered backup ring
Stem thrust washer
Handle
Packing bolt/stem assembly
Packing bolt gasket
Valve body
Packing bolt
Stem assembly
End screw assembly
Valve assembly
Sealing surface

5
Stem Seal Maintenance
Reassembly
6. Wipe packing bolt and stem clean with a lint-free
cloth.
7. Apply a thin film of lubricant to the stem thrust
washer and stem O-ring. Place parts on stem in
order and orientation shown.
8. Insert the stem assembly into the packing bolt.
CAUTION
Do not pinch the stem assembly components
when inserting into the packing bolt. The
components could be damaged and leakage
result.
9. Remove the valve assembly from the vise and tilt to
remove the ball. Rotate stem if necessary.
10. Place the packing bolt gasket into the body.
11. Thread packing bolt/stem assembly in valve body and
tighten by hand until it meets resistance.
12. Torque the packing bolt to 200 to 250 in.·lb (22.6
to 28.2 N·m, 230 to 290 cm·kg). Put the stem in the
closed position.
13. Pull stem up and install ball. Make sure the stem tang
is aligned with the slot on the ball. Push down on the
stem and rotate to the open position.
Packing bolt
Stem assembly
Stem O-ring
Stem backup ring
Chamfered backup ring
(chamfer side up)
Stem thrust washer Note: If also performing seat seal maintenance on the
removed end screw, follow step 5 of Seat Seal
Maintenance, Disassembly and steps 6 through
11 of Reassembly before proceeding with stem
seal maintenance.
14. Ensure the end screw gasket is resting on the
sealing surface of the end screw. Orient the end
screw assembly as shown and screw into the valve
assembly until no threads are visible.
15. Place the valve assembly into the vise. Torque the end
screwn to 300 to 350 in.·lb (33.9 to 39.5 N·m, 345 to
403 cm·kg).
NOTICE
Ensure end screw gasket remains on sealing
surface or damage to the gasket could result.
16. Place the handle on the valve stem, aligning the larger
stem flat and set screw hole, with the set screw hole
opposite the logo side of the valve. Tighten set screw
with a hex key.
17. Test the fully assembled valve for proper operation
and leak-tight integrity.
Stem tang Ball slot
End screw assembly
Valve assembly
Sealing surface
Stem step
Stem
step

1. Loosen the set screw using a hex key.
2. Remove the handle.
3. Place the new handle on the valve stem, aligning the
larger stem flat and set screw hole, with the set
screw hole opposite the logo side of the valve.
4. Thread the set screw into the handle and tighten with
a hex key.
5. Test the valve for proper operation.
Nylon Handle Kit
Tools Required
Handle
Set screw
Hex key
3/32 in.
Swagelok—TM Swagelok Company
© 2007, 2008 Swagelok Company
May 2008, R1
MS-CRD-0102
Set screw
Handle
Larger stem flat
Set screw hole
Logo side