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4Regulator Assembly and Disassembly Procedures
4 Regulator Assembly and Disassembly Procedures
1-1Tools
The table below shows the tools required for the disassembly and assembly of KR76-9***-V.
Tool name and dimensions Required tools are indicated with Regulator model
Name B KR76-9***-V Part name
Hexagon socket head bolt Buried plug (PT screw) ROH plug VP plug (PF screw) Hexagon socket head stop screw
Hexagon bar wrench 2 - - - M4 2.5 - - - M5 3 - - - M6 4 M5 Rc 1/16 - M8 5 M6 Rc 1/8 - M10 6 M8 Rc 1/4 G 1/4 M12, M14 8 M10 Rc 3/8 G 3/8 M16, M18 10 M12 Rc 1/2 G 1/2 M20 14 M16, M18 Rc 3/4 G 3/4 17 M20, M22 Rc 1 G 1 19 M24, M27 - - 21 - - - 22 M30 - - -
Closed wrench Socket wrench Double-head (single-head) wrench
19 M12 - G 1/4 22 - - G 3/8 24 M16 - - 27 M18 - G 1/2 30 M20 - - 36 - - G 3/4 41 - - G 1 50 - - G 11/4 55 - - G 11/2 Monkey wrench - Medium-sized × 1 Screwdriver - Medium-sized flathead screwdriver × 2 Hammer - Plastic hammer × 1
Pliers
- TSR-150 for stop ring - TRR-150 for locking ring Steel rod - Diameter φ4 or less L = 100 Torque wrench - With adjustable specified torque tightening Bolt for retrieving adjusting ring Q - M4 coarse head bolt
1-2Disassembly preparations (1)These regulators are configured with small precision parts, so disassembly and assembly requires rather complex operations. Read the entire section below on the maintenance procedures, and follow the procedure for disassembling the pump. (2)The regulator on the front and the rear are of different model. So mark the regulators when disassembling to differentiate between the drive side and the driven side. (3)The numbers in parentheses after the part names indicate the codes in the cross-section diagrams of Figures 1 and 2 (pages 303 and 304).
1-3Disassembly procedure 1. Select the location for disassembling the pump.
Precautions (1)Find a clean location to assemble the regulator. (2)Place a rubber plate or cloth on the work table so as not to damage the parts.
2. Use cleaning oil to remove any dirt or rust from the surface of the regulator.
3. Remove hexagon socket head bolts (438), and remove the cover (C) (629).
Precautions (1)The cover (C) is assembled with an the adjusting screw (C) (628), adjusting ring (C) (627), lock nut (630), hexagon nut (801), and the hexagon socket head stop screw (924). Do not loosen these screws and nuts. Doing so changes the adjusted pressure-flow setting.
4. After removing the cover (C) (629) subassembly, remove the outer spring (625), inner spring (626), and spring seat (C) (624) from the compensation section, and pull out the adjusting ring (Q) (645), pilot spring (646), and spring seat Q (644) from the pilot section.
Precautions (1)The adjusting ring (Q) (644) can be easily removed by pulling it out with an M4 bolt.
5. Remove the hexagon socket head bolt (436), and remove the pilot covers A and B (641). Remove the ROH plug (467) of pilot cover and remove the Pf sleeve (631) and pin (898).
6. Remove the setting spring (655) from the pressure regulation unit. Remove the stop ring (814), and remove the spring seat (653), return spring (654) and sleeve (651).
Precautions (1)The sleeve (651) is assembled with the snap ring (836). (2)When removing the stop ring (814), the return spring (654) flies out, so be careful not to lose this part.
7. Remove the locking plug (616), and remove the fulcrum plug (614) and adjusting plug (615).
Precautions (1)The locking plug may be damaged when removing. (No functional problem is present if the locking plug is not available.)
Precautions (1)This can be easily removed by using a pair of tweezers.
9. Pull out the pin (874), and remove the feedback lever (611).
Precautions (1)Use a fine steel rod to push out the pin (874) (pin diameter φ5) from above without touching the lever (1) (612).
11.Pull out the pilot piston (643) and spool (652).
12.Pull out the piston case (622), compensation piston (621) and compensation rod (623).
Precautions (1)The piston case (622) can be removed by pushing out the compensation rod (623) from the opposite side of the piston case (622).
B (641). Remove the hexagon socket head bolt (439), and remove the valve casing (656). Remove the electromagnetic proportional pressure reducing valve (079).
The regulator main unit is now disassembled.
Precautions (1)Be careful not to damage the connector of the electromagnetic proportional pressure reducing valve (079). <<Caution>> (1) The component parts are small, so be very careful not to lose them.
1-4Assembly procedure
The assembly procedure is the reverse of the disassembly procedure. However, follow the precautions below. (1)Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. (2)Any foreign matter entering the equipment can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. (3)Be sure to coat sliding parts with clean hydraulic oil before assembling. (4)As a rule, replace all O-rings and other seal parts with new parts. (5)Use a torque wrench to tighten all installation bolts and plugs to the standard torque specified in the maintenance standards.
1. Select the location for assembling the regulator.
Precautions (1)Find a clean location to assemble the regulator. (2)Place a rubber plate or cloth on the work table so as not to damage the parts.
2. Assemble the compensation rod (623) into the compensation opening on the casing (601).
3. Insert the pin (875) press fitted in the lever (1) (612) into the groove on the compensation rod (623), and assemble the lever (1) (612) to the pin (875) press fitted in the casing (601).
4. Assemble the spool (652) and sleeve (651) into the pressure relief hole on the casing (601).
Precautions (1)Check that the spool (652) and sleeve (651) slide smoothly into the casing (601) without catching. (2)Be careful to assemble the spool (652) in the correct direction.
5. Assemble the feedback lever (611), and insert the pin (874) while aligning it with the pin opening on the feedback lever (611).
Precautions (1)This is easier to assemble by inserting the pin (874) into the feedback lever (611) in advance. (2)Be careful to assemble the feedback lever (611) in the correct direction.
6. Assemble the pilot piston (643) into the pilot (643) opening on the casing (601).
Precautions (1)Check that the pilot piston (643) slides smoothly without catching.
8. Install the fulcrum plug (614) so that the pin (875) press fitted in the fulcrum plug (614) is inserted into the pin opening on the lever (2) (613).
9. Install the adjusting plug (615). Install the locking plug (616), if necessary.
Precautions (1)Be careful to insert the fulcrum plug (614) and adjusting plug (615) into the correct insertion hole. (2)At this time, check that play of the feedback lever (611) movement is not too great and that the feedback lever (611) does not catch on anything.
10.Install the return spring (654) and spring seat (653) into the sleeve (651) and install the stop ring (814) to the spool (652).
11.Assemble the set spring (655) into the adjusting hole, and assemble the compensation piston (621) and piston case (622) into the compensation opening.
12.Install the Pf sleeve (631), pin (898) and
ROH plug (467) to each pilot cover (641) and tighten them with hexagon socket head bolts (436). Install the electromagnetic proportional pressure reducing valve (079) to the pilot cover A (641) of KR76-9Y2C-V, and install the electromagnetic proportional pressure reducing valve (079) to the valve casing (656) of KR76-9X2D-V.
Precautions (1)Check that the pin (898) moves smoothly. (2)Be careful not to damage the connector of the electromagnetic proportional pressure reducing valve (079).
13.Install the spring seat (Q) (644), pilot spring (646), and adjusting ring (Q) (645) into the pilot opening, and install the spring seat (Q) (624), inner spring (626), and outer spring (625) into the compensation opening.
Precautions (1)Be careful to assemble the spring seat (Q) (644) and spring seat (C) (624) in the correct direction.
14.Assemble the cover (C) (629) with the set adjusting screw (C) (628), adjusting screw (Q) (925), adjusting ring (C) (627), lock nut (630), hexagon nut (801), and hexagon socket head locking screw (924), and tighten hexagon socket head bolts (438).
The regulator main unit is now assembled.
Breakdown diagram
Note: (K) (L) (M) (N) in this diagram shows the installation locations of pump casing. “See pump breakdown diagram (drawing No. 02440-3916)”
Breakdown diagram
Note: (W) (X) (Y) (Z) in this diagram shows the installation locations of pump casing. “See pump breakdown diagram (drawing No. 02440-3916)”
