Swagelok KCP Series Technical specifications

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

2
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
LP
High pressure
Piston
Piston seal
Discard
Piston seal
Discard
Piston guide
Filter pick tool
Discard
inlet filter.
HP Inlet port

3
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
Poppet spring
Seat retainer assembly
Body
Low pressure
Lubricate
lightly
High pressure
Lubricate lightly
Lubricate lightly
Concave side
Body cap assembly
Spring button
Dimple
Lubricate lightly
Piston assembly
Body
Body
threads
Lubricate lightly
Lubricate lightly
Bottom face
Body cap
assembly

4
Swagelok — TM Swagelok Company
© 2008, 2014, 2015 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.
HP
Inlet lter
Filter insertion tool