Swagelok KHR Series Technical specifications

Symbols
Lightly lubricate
Discard
Kit Contents
KHR Series Regulators
Maintenance Instructions
Poppet damper
Lubricant
MS-LT-WL8
Outer body seal
Seat retainer
Upper piston seal
Self-vent seat Self-vent poppet
Seat
Inner body seal
Poppet spring
Inlet Filter
Self-vent seat retainer
Piston vent seal Self-vent poppet spring
Poppet
Main piston sealPiston seal backup ring

NOTE: See Pressure Regulators, MS-02-230, for tool ordering information.
Tool Size Component
Vise
-Body
Socket
5/8 in. or 16 mm Seat retainer
Crow’s foot
1 5/8 in. or 41 mm Body cap
3/4 in. or 19 mm Vent assembly retainer nut
Open-ended wrench
1 5/8 in. or 41 mm Body cap
3/4 in. or 19 mm Vent assembly retainer nut
Torque wrench
Capable of
129 ft·lb (175 N·m, 17.9 m·kg)
Seat retainer,
Body cap,
Vent assembly retainer nut
Hex key
1/8 in. or 3 mm Vent screw,
Upper spring button set screw
Needle-nose pliers
-Knob handle retainer
Swagelok Tools Available
Vent retainer tool
-Self-vent seat retainer
Piston assembly bar
- Piston
Filter insertion tool
—Inlet filter
Filter pick tool
—Inlet filter
Tools Required
2

Exploded View
Seat Assembly
Self-Vent Assembly
Stem Assembly
Cover
Handle retainer
Handle
Outer body seal
Body
Seat retainer
Seat
Stem
Upper spring
button
Piston seal backup ring
Upper piston seal
Piston
Poppet damper
Poppet spring
Poppet
Upper
spring
button
set
screw
Stem nuts
Lower spring
button
Range spring
Thrust roller
bearing
Piston guide
Body cap
Self-vent poppet
Self-vent poppet spring
Self-vent seat retainer
Self-vent seat
Inlet lter
Vent rod / screw
Vent screw spring
Vent rod nut
Main piston seal
Piston vent seal
Inner body seal
3

4
5. Remove the body cap from the body.
Note: The range spring and the lower spring button may
fall from the body cap. Set aside for later use.
6. Remove the piston guide from the body by pinching the
piston top with your ngers and gently rocking it.
7. Lightly grip the piston guide in the vise and remove the
self-vent seat retainer from the piston guide using the
piston assembly bar and the vent retainer tool. The
piston assembly bar must be held still.
WARNING
Before removing a regulator from the system for
service, you must
•  depressurizesystem
•  purgethesystemtoremoveanyresidual
system media left in the regulator.
Disassembly
1. Place the regulator in a vise.
2. Turn the handle counterclockwise until it stops. Remove
the cover, the handle retainer and then pull the handle
from the body.
Note: Use needle-nose pliers to remove the handle retainer.
3. Remove the vent screw / rod and vent screw spring from
the stem, and set aside for later use.
4. Loosen the body cap.
Body cap
Handle
Handle retainer
Cover
Body cap
Range spring
Lower spring
button
Body
Stem
Piston assembly bar
Piston guide
Vent retainer tool
Piston guide
Body
Piston

12. Loosen and remove the seat retainer. Discard the seat
and seat retainer.
NOTICE
Be careful not to scratch the inside of the body.
Leakage could result.
13. Invert the body and remove the poppet, the poppet
spring, and the poppet damper.
14. Remove the inlet filter using the filter pick tool or similar
tool, and remove the filter from the inlet port (marked
‘HP’) of the body.
NOTICE
Be careful not to scratch the sides of the inlet
port. Leakage could result.
8. Remove the self-vent poppet spring, the self-vent
poppet and the self-vent seat from the piston guide.
9. Push the piston out of the piston guide.
10. Grip the vent rod nut in the vise, and loosen and remove
the nut by using the piston assembly bar. Set aside the
nut for later use. Remove the piston vent seal from the
piston.
11. Remove the upper piston seal from the top of the piston
guide, and the main piston seal and the piston seal
backup ring through the bottom of the piston guide.
Remove the outer body seal and the inner body seal
from the body.
5
Self-vent seat
Self-vent poppet
Self-vent poppet spring
Piston guide
Piston guide
Piston
Piston
assembly bar
HP
Inlet port
Filter pick tool
Discard
inlet lter
Poppet damper
Poppet
Poppet spring
Outer body seal
Body
Inner body seal
Piston guide
Main piston seal
Piston seal backup ring
Upper piston
seal
Body
Seat retainer
Seat
Piston vent seal
Piston

Reassembly
NOTICE
Ensure all parts and tools are free of debris or
damage.
15. Insert the seat into the seat retainer with the groove facing
away from the seat retainer.
16. Place the poppet through the seat. Then place the poppet
spring and the poppet damper onto the exposed end of
the poppet.
17. Invert the body and thread the seat assembly into the body
nger-tight.
18. Tighten the seat assembly to:
for non-metallic seat: 13 ft·lb (17.5 N·m, 1.8 m·kg)
for metallic seat: 26 ft·lb (35.0 N·m, 3.7 m·kg)
19. Insert the inlet filter using the filter insertion tool into the
inlet (marked ‘HP’) of the body.
NOTICE
Do not insert with sharp tools. Damage to filter
could result.
20. Insert the upper piston seal into the groove in the top of
the piston guide. Insert the piston seal backup ring,
followed by the main piston seal through the bottom of
the piston guide. Insert the outer body seal and inner
body seal into the body.
21. Insert the piston vent seal and thread the vent rod nut
into the piston.
22. Invert the piston and insert the self-vent seat with the
groove facing away from the piston. Then insert the
self-vent poppet and the self-vent poppet spring into
the piston. Finger-tighten the self-vent seat retainer into
the piston using the vent retainer tool.
6
Seat assembly
Body
Seat
Seat retainer
Groove
Self-vent seat
Piston
Self-vent poppet
Self-vent poppet spring
Vent retainer tool
Self-vent seat retainer
Groove
Poppet
Poppet spring
Poppet damper
Seat
Piston vent seal
Vent rod nut
Piston
Outer body seal
Body
Inner body seal
Piston
guide
Upper piston seal
Main piston seal
Piston seal
backup ring
Apply non-permanent
thread locking uid.
Filter insertion tool
Inlet lter
HP
Inlet
Body

23. Grip the vent rod nut in the vise and tighten to 3.5 ft·lb
(5N·m, 0.5 m·kg).
24. Lightly grip the piston guide in the vise and insert the
piston assembly into the piston guide. Then tighten the
self-vent seat retainer to 7 ft·lb (10 N·m, 1.0 m·kg) using
the piston assembly bar and vent retainer tool.
NOTICE
Do not force the piston assembly into the piston
guide. Damage to the seals could result.
25. Insert the piston guide into the body. Lightly press down
on the piston guide until it is fully seated.
NOTICE
Do not pinch the body seals. Damage could
result.
26. Place the range spring and the lower spring button into
the body cap. Thread the body cap nger-tight into the
body in the inverted position.
27. Tighten the body cap to 129 ft·lb (175 N·m, 17.8 m·kg).
28 Place the handle and the handle retainer on the body
cap.
7
Piston assembly bar
Vent retainer tool
Piston guide
Handle
Handle retainer
Body cap
Body cap
Vent retainer tool
Piston guide
Body
Body cap
Body
Lower
spring
button
Range
spring

8
29. Insert the vent screw spring into the stem. Thread the
vent rod / screw three or four turns onto the stem. Do not
fully tighten.
30. Test regulator for proper operation.
31. Apply 50 to 100 psig (3.4 to 6.8 bar) to the LP port, tighten
the vent screw until leakage is heard, and then loosen by
one-half turn.
Swagelok — TM Swagelok Company
© 2010 — 2015 Swagelok Company
October 2015, R3
MS-CRD- 0141
For additional information, see www.swagelok.com.
32. Place the cover on the handle
Cover
Handle
Vent screw spring
Vent rod / screw
Body cap
Stem
Stem
LP