Swagelok KCP Series Technische Daten

KCP Series Regulators

Maintenance Instructions

Kit Contents

Poppet Poppet spring

Lubricant (with MSDS)

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.

Inlet Filter

High pressure kits

only

(over 250 psig

[17.2 bar])

Piston guide seal

Seat retainer

Seat Piston seal

ToolsRequired

Tool Size Component

Socket

5/16 in. Seat retainer

Crow’s foot

1 1/4 in. Body cap

Open-ended wrench

1 1/4 in. Body cap

Torque wrench Capable of

11.2 ft·lb (15.2 N·m, 1.6 m·kg) Seat retainer

Capable of

25 ft·lb (33.9 N·m, 3.5 m·kg) Body cap

Swagelok Tools Available

Filter insertion tool

—Inlet filter

Filter pick tool

—Inlet filter

Disassembly

1. Place the regulator in a vise.

Note: Take precautions to protect the body from

being scratched by the vise.

2. Turn handle counterclockwise until it stops.

3. Loosen bodycap.

4. Remove capassembly and handle as one piece and

set aside for later use.

Note: In high-pressure regulators (over 375 psig [25.8

bar]), the lower springbutton may fall from the cap

assembly when lifted. Set aside for later use.

5. Turn body assembly upside down and remove piston

assembly by applying low-pressure air to an outlet

portmarked ‘LP’.

CAUTION

Applyingpressuregreaterthan5psig

(0.34bar)couldcausepersonalinjuryor

damagetothepiston.

6. Remove the pistonseal(s). For high pressure

regulators, also remove the pistonguide.

7. Use socket wrench to remove seat assembly,

poppet,andpoppetspring.

CAUTION

Becarefulnottoscratchtheinsideofthe

body.Leakagecouldresult.

Note: If your regulator assembly is used on a Swagelok

MPC substrate, proceed to step 9.

8. Remove the inlet ﬁlter from the inletport(marked

‘HP’) using thelterpicktool. Discard old lter.

NOTICE

Becarefulnottoscratchthesidesoftheinlet

port.Leakagecouldresult.

Cap assembly / handle

Over 375 psig

regulators

Lower spring

button

Body cap

Handle

Piston seal

Low pressure

Piston

Discard

Poppet spring

Seat retainer

assembly

Discard Poppet

Low pressure

piston assembly

Outlet port

High pressure

Piston

Piston seal

Discard

Piston seal

Discard

Piston guide

Filter pick tool

Discard

inlet filter.

HP Inlet port

Reassembly

CAUTION

Ensureallcomponentsarefreeofdebrisor

damageorleakagecouldresult.

9. Fit the seat into the seat retainer until ush. Lightly

lubricate the threads only.

10. Place the poppet through the center of the seat.

11. Place the poppetspring onto the exposed end of the

poppet.

12. Keep the seat retainer assembly inverted with the

poppet spring on the top and thread it into the body.

13. Tighten seat retainer to 11.2 ft·lb (15.2 N·m, 1.6 m·kg).

14. Lightly lubricate pistonseal(s) and install onto

piston. For the high pressure piston, press the

second seal onto the piston guide from the concave

side.

15. Press the pistonassembly into the body until it

seats against the seat retainer.

Note: Do not to damage the piston seals.

16. High pressure regulators only, put a small amount of

lubricant in the the dimple of the springbutton and

place into the bodycapassembly.

17. Lightly lubricate the bodythreads and the bottom

face of the bodycapassembly.

Lubricate lightly

Seat

Seat retainer

Seat

Poppet

Poppet spring

Seat retainer assembly

Body

Low pressure

Lubricate

lightly

High pressure

Lubricate lightly

Concave side

Body cap assembly

Spring button

Dimple

Lubricate lightly

Piston assembly

Body

threads

Lubricate lightly

Bottom face

Body cap

assembly

Swagelok — TM Swagelok Company

October 2015, R3

MS-CRD-0109

For additional information, see www.swagelok.com.

18. Thread body cap assembly onto body. Tighten to

25 ft·lb (33.9 N·m, 3.5 m·kg).

Note: If your regulator assembly is used on a Swagelok

MPC substrate, proceed to step 20.

19. Insert inlet ﬁlter in the inlet port (marked ‘HP’) using

the ﬁlter insertion tool.

NOTICE

Donotinserttheinletlterwithasharptool.

Damagetotheltercouldresult.

20. Test and set the regulator for proper operation.

Inlet lter

Filter insertion tool

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