INSTRUCTION MANUAL

PNEUMATIC DOUBLE ACTING CYLINDER OPERATED

MULTI HOLE CAGE TYPE CONTROL VALVE
6300LA/550G
UP TO CLASS 600#
 INTRODUCTION

This operation manual is a guidebook for our Pneumatic Double Acting Cylinder Operated
Multi hole Cage Type Control Valve, which is a combination of our Series-6300LA
Pneumatic Double Acting Cylinder Actuator and our Series-550G Multi hole Cage Type
Control Valve. It should not be used for the operation of control valves of other models.

We believe that this manual could be helpful not only to new users of KOSO Pneumatic
Double Acting Cylinder Operated 550G Series Multi hole Cage Type Control Valves, but
also to those who have experience in the use of them because this manual will help them
recognize their knowledge and experience. Please read it carefully to fully understand its
contents before you actually operate this control valve. After the start of the regular
operation of your plant in which this control valve is installed, we suggest that this manual
be always kept readily available to the plant operators and maintenance engineers for help
whenever in need.

The main contents of this manual comprise the receiving, handling and storage, unpacking,
installation, preparations for operation and operation, structure, principle of operation,
daily and regular inspection, troubleshooting and remedies, and disassembly and
reassembly.

Latest results of our ever ongoing research and improvement activities on the design of our
Pneumatic Double Acting Cylinder Operated 550G Series Multi hole Cage Type Control
Valve may not be fully reflected in every detail on the control valve you have purchased.
Should you have any question about the KOSO control valve you have purchased or the
contents of this manual, please feel free to contact your local suppliers.
 SAFETY PRECAUTIONS

Proper handling and regular maintenance of the Pneumatic Double Acting Cylinder
Operated Multi hole Cage Type Control Valve are essential for the safe performance of its
receiving, hoisting, storage, installation, preparations for operation. Before you actually
handle and operate this control valve, please carefully read and understand the safety
precautions given in this manual.

The safety precautions provided in this manual for the operation and safety are intended to
be observed only when the Pneumatic Double Acting Cylinder Operated 550G Series
Multi hole Cage Type Control Valve is used to regulate the flow rate of a process fluid for
the purpose of controlling the flow rate, pressure, temperature and liquid level in the
process system or used for the purpose of ON-OFF control. The users of this control valve
are responsible for all safety cautions and care required for operations not covered under
this manual.

In this manual, the "cautions" that need to be exercised with particularly careful attention
are noted, where applicable, in a frame containing the heading WARNING or CAUTIONS
followed by its respective, specific description.

! WARNING
Addresses cautions non-observance of which can lead to injury or death of person.

! CAUTIONS
Addresses cautions non-observance of which can lead to failure or damage to this
control valve or other equipment.

!CAUTIONS
End user shall make proper earthling arrangement to discharge the accumulated
static electricity
 CONTENTS
Pages
1. Receiving, Handling and Storage -------------------------------------------------------- 1~2
1-1. Receiving and Handling
1-2. Storage
2. Unpacking ----------------------------------------------------------------------------------- 3
3. Installation ---------------------------------------------------------------------------------- 4~6
3-1. Allowable Ambient Temperature for Installation
3-2. Space for Maintenance and Facilities
3-3. Installation Position
3-4. Piping and Wiring
4. Preparations for Operation, and Operation --------------------------------------------- 7 ~ 10
4-1. Preparations for Operation
4-2. Operation
5. Structure ------------------------------------------------------------------------------------- 11 ~ 14
5-1. Double Acting Type Actuator
5-2. Top/side handle type operation mechanism
5-3. Top handle type operation mechanism
5-4. Valve Assembly
6. Principle of Operation --------------------------------------------------------------------- 15
7. Daily Inspection and Periodic Inspection ----------------------------------------------- 15 ~ 17
7-1. Daily Inspection
7-2. Periodic Inspection
8. Troubleshooting and Remedies ---------------------------------------------------------- 18
9. Preparations for Disassembly ------------------------------------------------------------ 19
10. Disassembly and Reassembly ------------------------------------------------------------ 20 ~ 28
10-1. Separation of Actuator from Valve Assembly
10-2. Disassembly of Actuator
10-3. Disassembly of Valve Assembly
10-4. Reassembly of Valve Assembly
10-5. Reassembly of Actuator
10-6. Reassembly of Actuator and Valve
10-7. Reassembly of Actuator Accessories
11. Adjustment after Reassembly ------------------------------------------------------------ 29
12. Disposal of Product or Parts -------------------------------------------------------------- 29
13. Maintenance Parts -------------------------------------------------------------------------- 30
1. Receiving, Handling and Storage
1-1. Receiving and handling

! WARNING
This control valve is heavy and therefore needs to be handled carefully and properly,
following the instructions given below. Failure to observe these instructions may
cause serious injuries on persons.
• For hoisting up and down the package containing this control valve, use a suitable
hoisting machine conforming to the requirements of the labor safety and hygiene
acts. Do not allow any person to be beneath the package being hoisted up, nor
operate the hoisting machine beneath the package being hoisted up.
The weight of this control valve is indicated on a surface of the package.
• For a small-sized control valve contained in a cardboard box, the strength of the
cardboard box will be reduced as it is wetted. When the cardboard box is wetted,
carefully handle it accordingly.

1-2. Storage
(1) It is recommended that the control valve be stored in an as-received packed state until
the work to install it in a piping is started.
(2) Do not store it in a place:
(a) Exposed to rainwater;
(b) Where ambient temperature is higher than 60°C.
(c) In a dusty environment; and/or
(d) In a humid atmosphere.
(3) Even when the received control valve has been unpacked and inspected for
acceptance, it is recommended that the control valve be repacked as received and
stored.
(4) Do not remove the air supply line plugs and electric conduit connection plugs and
covers until the air pipe connecting and electric wiring works are commenced.
(5) If the received, as-packed control valve is going to be stored for one year or more, the
gland packing may be hardened and degraded during the storage. To prevent the
degradation, open the top of the package, loosen the gland flange locking hexagon
nuts by about two turns, and store the valve, repacked. Before using the control valve
that has been long stored as above, tighten the hexagon nuts to a torque value shown
in Tables 10-2. Then apply an air pressure or hydraulic pressure equivalent to the
operating fluid pressure (or apply nitrogen gas pressure if the fluid pressure is higher
than 0.95 MPa) into the control valve through the pipe connection flange, and check
the gland packing for leakage. If leakage should be detected, replace the gland
packing with a new one. For the replacement, follow the procedure described in
section 10, Disassembly and Reassembly.

1
(6) To store the control valve after use, treat the control valve as follows.
(a) Clean the inside of the control valve by washing with water, and then dry it.
(b) Keep butt weld and connection surfaces free from being damaged, denoted by
arrows in Fig. 2-1, against damage.
(c) Apply rust preventive treatment to control valve parts that are liable to rust.
(d) Protect the air supply connection and electric conduit connections of the control
valve with water resisting treatment.

2
2. Unpacking
Follow the unpacking instructions stated on the surface of the package.

! WARNING
• When hoisting up this control valve out of its package, use standardized hoisting
belts suited for the weight of this control valve, to ensure damage-free handling of
the control valve. For setting the hoisting belt on the control valve, refer to Fig. 2-2.

! CAUTIONS
When and after the control valve is unpacked, take care to protect the control valve
against its performance deterioration, as follows.
• Keep the butt weld end connection surfaces (for connection to the piping) free from
being damaged. See Fig. 2-1. Damaged end surface can be a cause of fluid leakage
from the end connection with the piping.
• If your control valve is a model having an actuator fitted with appurtenances such as
a positioner, a booster relay and a solenoid valve or with a manual operation
mechanism, make sure not to apply any load of the hoisting belt on these devices.
When the control valve is put on a floor, ensure that the accessory devices and
manual operation mechanism do not touch the floor to prevent them from being
damaged by the load of the control valve.

Protect the surfaces, pointed

by arrows, from damage.
Without manual operation mechanism With manual operation mechanism
Fig. 2-1 Fig. 2-2

3
3. Installation

! WARNING
This control valve is heavy and therefore needs to be handled carefully and properly,
following the instructions given below. Failure to observe these instructions may cause
serious injuries on persons.
• For installing this control valve in your process piping, hoist it using a hoisting
machine conforming to the requirements of the labor safety and hygiene acts. Do not
allow any person to be beneath the package being hoisted up, nor operate the
hoisting machine beneath the package being hoisted up.
The weight of the control valve is shown on the front side of the packing box.

! CAUTIONS
To maintain the performance of this control valve, exercise cautions as follows.
• Keep the butt weld end connection surfaces free from being damaged. If the end
connection is of flange type, then keep the gasket mounting surfaces of the flanges
(for connection to the piping) free from being damaged. See Fig. 2-1.Damaged end
surface can be a cause of fluid leakage after connecting with the piping system
• When hoisting up this control valve out of its package, use standardized hoisting
belts suited for the weight of this control valve, to ensure damage-free handling of
the control valve. Observe the WARNING and CAUTIONS given on page 3,
Unpacking.
• Prior to the connection of the control valve to a process piping, clean the inside of
the piping to remove dust, sand, welding spatter and other foreign inclusions from
the piping. Foreign inclusions, if left in the piping, and may be caught between the
plug and the seat ring to cause leakage. Foreign inclusions, if allowed to enter the
guide of the plug, may disturb its operation.
• Foreign inclusions, if left in the piping, and may be caught between the plug and the
seat ring to cause leakage. And if allowed to enter the stem bearing, it may disturb its
operation.
• Do not remove the plugs at the air pipe and electric conduit connections of this
control valve until the connection of this control valve to the process piping is
completed and until the piping and the wiring works are started.
• When installing this control valve in the process piping, avoid applying such hard
impacts to it as dropping it or bumping it hard.
• If the actuator of the control valve is fitted with a manual operation mechanism,
provide a sufficient space to permit safe and easy operation of the manual operation
mechanism.
• Do not install this control valve in a place the control valve may be subject to hard
vibration or heavy loading.
• Do not attempt to ease the maintenance of the control valve by installing it in such a
manner as causing the actuator to be positioned upside down.
• Maintain the ambient temperature of the installed control valve within the range
specified in subsection 3-1, Allowable ambient temperature for installation.

4
3-1. Allowable ambient temperature for installation
There are three ambient temperature ranges; those are "Standard", "High temperature"
and "Low temperature". The range depends on the ambient temperature value, which you
have specified while placing the order with us. According to this your control valve is
＊
manufactured. Referring to the temperature ranges shown below , select a suitable place
for installation where the specified ambient temperatures for your control valve could be
met.
If the ambient temperatures around the selected place for installation may possibly exceed
the specified range on account of the direct sun or solar radiation, provide an adequate
sunshade or protect the control valve with heat insulation.
＊Standard range : -20 to +60℃
＊Low-temperature range : -50 to +60℃
＊High-temperature range : 0 to +100℃

3-2. Space for maintenance and facilities

Above the control valve installed, maintain a space necessary for replacement of the
actuator as well as for inspection of the inside of the control valve. When the valve is too
heavy to remove for maintenance, provide a fixture (metal) for mounting a chain block
on top of the valve. Actually, add the chain block hook dimension to the dimension H
shown below.

Valve size H
Below 8” ( Below 200A) 600 mm or more UP
10” to 14” (250A to 350A) 800 mm or more
Above 16” (Above 400A) 900 mm or more

3-3. Installation position

• As a rule, the position of the installed control valve
should be vertically as illustrated in Fig. 3-1.
DOWN
• Only when the vertical installation is impracticable,
the control valve may be installed in a position
within the range shown in Fig. 3-2, provided that
the attached exhaust port of the actuator is not
directed up. If the installed control valve is liable to Fig. 3-1
external vibration or forces, an appropriate support
should be provided for the control valve or the
piping.
• If your control valve is fitted with a manual
operation mechanism, the control valve should be
installed in a position to ensure safe and easy
operation of the mechanism.

Fig. 3-2

5
3-4. Piping and wiring

! CAUTIONS
• For operating source of the actuator, use dry and clean instrumentation air.
• For air pipe connections to the instruments such as the positioner and the
booster relay, use pipes having a diameter that may not cause pressure drop in
the piping.
• For a control valve factory-equipped with a positioner, booster relay and
solenoid valve as standard accessories, the air piping from these accessories to
the actuator have been already completed and delivered. Be careful not to
damage these air pipes.
• When the accessory devices are connected to the valve, air piping and wiring
for instrumentation should be performed according to the instruction manual
for each device.
• Do not use sealing tapes for instrumentation air supply pipe connections to the
accessories because a sealing tape, if used there, may be jammed in to cause
malfunction of the instruments.
• Do not perform wiring work on a rainy day or in an environment where the
control valve is exposed to drops or splashes of water, in order to avoid
possible electric leakage and subsequent damage to the instruments.
• For wiring, use wires having an enough capacity for the performance of the
instruments.
• Make certain that the wires connected to the instruments may not allow rain
water and other water to run from the lead-in wires into the instruments.

6
4. Preparations for Operation, and Operation
4-1. Preparations for operation
All adjustments based on your order specifications received by KOSO are completed
before the control valve is shipped from the factory. However, in view of possible shocks
or impacts on the control valve during its transportation and installation work, check its
performance in combination with the controller or ON/OFF control circuit after
completion of the installation work.

! CAUTIONS
• If the actuator of your control valve is fitted with accessories, do not prepare for
operations on a rainy day or in an environment where the control valve is
exposed to drops or splashes of water, to avoid possible electric leakage and
performance degradation.
• For accessories that require power supply, check the voltage specified on their
nameplates for conformance to your power source before connecting them to
the power source. If your power supply does not meet the voltage specified on
the nameplates, adjust your power supply to meet the specified voltage.
• Use dry and clean air to operate the actuator. The air pressure must not exceed
the set value shown in the specifications. If it needs to be changed, contact
KOSO for advice.
• Make sure that the air is not leaking from the joints of the instrumentation air
piping and from tightened parts of the actuator, output shaft and stopper
mechanism. If the air is leaking, be sure to stop it referring to Item 10-2.
• The double-acting manual operation mechanism is provided with an equalizing
valve to unify the air pressure in the cylinder. Be sure that this equalizing valve
is fully tightened to avoid incorrect operation.

(1) Adjustment of accessories

When an adjustment is needed for an accessory, follow the instructions given in the
manual for that accessory. To detect the stroke of the control valve, for adjusting the
positioner use a dial gauge or a stroke detector similar to a dial gauge.

(2) Check of valve opening and closing

During transportation, storage or installation, the valve opening/closing position will
not get out of order. If, however, the actuator is separated from the valve assembly
during the installation work of the control valve by some reason or other, the actuator
should be assembled with the valve and adjusted referring to Item 10-6 “Reassembly
of actuator and valve assembly” and “Assembly of actuator with valve” and Item 11
“Adjustment after reassembly”. When a positioner is provided, perform adjustment
and check of accessory devices as noted above.

7
4-2. Operation

! CAUTION
• During operation, keep the covers of the accessories and the wiring terminal
box securely closed. If the control valve is operated with those covers left
open, rain water or liquids from the immediate vicinities may enter it to cause
electric leakage or shocks, or failure of the accessories.

(1) Manual operation

This is an optional accessory device. Manual operation is available for opening or
closing the valve when operating air pressure is not available. (Optional)

(1-1) Top/side handle type operation mechanism for double-acting type actuator
For the encircled part numbers, refer to Fig. 4-1 and 4-2.
• Open the equalizing valve 397 .
• Close the stop valve for supply air pressure. If the stop valve is not provided, reduce
the air pressure supplied to the actuator until zero using the air pressure reducing
valve.
• Turn the connecting fork 372 counterclockwise and remove it from the drive
shaft 345 .
• Remove the hand wheel lock pin 362 that is used to lock the hand wheel 348
during automatic operation.
• Turn the hand wheel clockwise and set the notch a in the drive shaft to the
groove b in the piston rod 106B , then insert the connecting fork.
• Turn clockwise the manual operation hand wheel, and the control valve will move in
the direction of closing. Turning it counterclockwise will move it in the direction of
opening.
• At the completion of manual operation, remove the connecting fork to set the valve
in automatic operation mode.
• Turn the hand wheel counterclockwise until it is set in automatic operation mode
(hand wheel stops turning), and insert the hand wheel lock pin.
Note that the control valve will not fully open if the hand wheel stops in the middle.
• Fully close the equalizing valve and reset the supply air pressure for operation.

8
 Manual operation
Fig. 4-1

Automatic operation
Fig. 4-2

9
(1-2) Top handle type operation mechanism for double-acting type actuator
For the encircled part numbers, refer to Figs 4-3 and 4-4.
• Open the equalizing valve 397 .
• Close the stop valve for supply air pressure. If the stop valve is not provided, reduce
the air pressure supplied to the actuator until zero using the air pressure reducing
valve.
• Turn the connecting fork 372 counterclockwise and remove it from the drive
shaft 345 .
• Turn the hand wheel 348 clockwise and set the notch a in the drive shaft to the
groove b in the piston rod 106B , then insert the connecting fork.
• Turn clockwise the manual operation hand wheel, and the control valve will move in
the direction of closing. Turning it counterclockwise will move it in the direction of
opening.
• At the completion of manual operation, remove the connecting fork to set the valve
in automatic operation mode.
• Turn the hand wheel counterclockwise until it is set in automatic operation mode
(hand wheel stops turning).
Note that the control valve will not fully open if the hand wheel stops in the middle.
• Fully close the equalizing valve and reset the supply air pressure for operation.

Fig. 4-3 Automatic operation

Fig. 4-4 Manual operation

10
5. Structure
5-1 Double acting type actuator
The 6300LA series double-acting cylinder type actuator is composed of a piston, cylinder,
piston rod and upper/lower cylinder cover. It is a most common linear stem motion type
control valve actuator.

AIR CONN.

AIR CONN.

＊ The piston guide 136 is

used only for 6345LA and
6360LA actuators.

＊ The hexagon socket set

screw 131 is not provided
with 6345LA and 6360LA
actuators.

Fig. 5-1. Configuration of 6300LA double-acting actuator and name of parts

No. Designation No. Designation No. Designation No. Designation
101 Yoke 110 Spring washer 119 Dust seal 128 Division plate
102 Cylinder cover A 111 Hexagon bolt 120 Retaining ring C-type 129 Cross recessed head screw
103 Cylinder cover B 112 Spring washer 121 Stopper A 130 Hexagon nut
104 Piston 113 Split ring 122 Stopper B 131 Hexagon socket set screw
105 Cylinder 114 Retaining ring 123 Eyebolt 132 Hexagon socket set screw
106 Piston rod A 115 O-ring 124 Spring washer 133 Guide plate
107 DU Bushing 116 O-ring 125 Connector 134 Cross recessed head screw
108 Cylinder rod 117 O-ring 126 Hexagon socket head cap screw 135 Hexagon nut
109 Hexagon bolt 118 O-ring 127 Conical spring washer 136 Piston guide

11
 5-2 Top/side handle type operation mechanism

Fig. 5-2 Configuration of 6300LA Top/side handle type operation mechanism and name of parts

No. Designation No. Designation No. Designation No. Designation

102 Cylinder cover A 350 Deep groove ball bearing 367 Spring pin 386 SUS wire rope
106B Piston rod B 351 Stopper nut 368 Sliding key 387 SUS wire rope
107 DU Bushing 352 Bellows 369 Retaining plate A 388 Connecting pipe
117 O-ring 353 Hexagon bolt 370 Retaining plate B 389 O-ring
119 Dust seal 354 Spring washer 371 Retaining ring C-type 390 Hexagon socket set screw
340 Gear case 355 Hexagon bolt 372 Connecting fork 393 Plain washer
341 Gear case cover 356 Spring washer 373 Retaining ring C-type 394 Fixing plate for instruction plate
342 Side cover 357 Hexagon bolt 374 Hexagon nut 395 Instruction plate
343 Bevel gear large 358 Spring washer 375 Spring washer 396 Rivet
344 Bevel gear small 360 Dust seal 376 O-ring 397 Equalizing valve
345 Drive shaft 361 Spring pin 377 O-ring
346 Screw nut 362 Hand wheel 378 O-ring
348 Hand wheel Lock pin 379 O-ring
349 Thrust ball bearing 366 DU Bushing 380 O-ring

12
 5-3 Top handle type operation mechanism

Fig. 5-3 Configuration of 6300LA Top handle type operation mechanism and name of parts
No. Designation No. Designation No. Designation
102 Cylinder cover A 354 Spring washer 381 Spring pin
106B Piston rod B 355 Hexagon bolt 382 Cross recessed head screw
107 DU Bushing 356 Spring washer 383 O-ring
117 O-ring 359 Bearing 384 Bearing spacer
119 Dust seal 363 Retaining ring C-type 385 Retaining ring C-type
340 Gear case 364 Washer 387 SUS wire rope
341 Gear case cover 367 Key 388 Connecting pipe
345 Drive shaft 368 Sliding key 393 Plain washer
346 Screw nut 372 Connecting fork 394 Fixing plate for instruction plate
347 Guide 373 Retaining ring C-type 395 Instruction plate
348 Hand wheel 376 O-ring 396 Rivet
349 Thrust ball bearing 377 O-ring 397 Equalizing valve
352 Bellows 379 O-ring
353 Hexagon bolt 380 O-ring

13
5-4.Valve assembly
The series-550G Multi hole cage guided control valve has the following structure. The
valve assembly is composed of a seat ring, a multi hole cage, a balance cylinder and a
bonnet stacked on a single seat of the valve body and fastened together with stud bolts
and hexagon nuts. When the valve assembly is reassembled in accordance with the
reassembling procedure, the centering of the seat ring and the plug is automatically
achieved to greatly ease the reassembly.

No. Designation
1 Body
2 Bonnet
3 Seat ring
4 Multi hole Cage
5 Plug
6 Stem
7 Balance Seal
8 Balance Cylinder
9 Seat Gasket
10 P/B Gasket
11 Bonnet Gasket
12 Packing seat
13 Lantern ring
14 Gland Packing
15 Packing follower
16 Wiper
17 Gland Flange
18 Body Stud bolt
19 Hexagon Heavy Nut
20 Gland Stud Bolt
21 Hexagon nut
Direction of flow
26 Balance Seal Spacer
：Over plug flow
：Under plug flow

Fig. 5-4 Internal structure and names of parts

Fig. 5-5 Detail A, Gland packing structure detail (Square Packing)

14
6. Principle of Operation
For the encircled part numbers, refer to Fig. 5-1.
When air pressure is supplied from the instrumentation air feed/discharge port A (cylinder
chamber on the instrumentation air feed/discharge port B is in the state of atmospheric
pressure), air pressure is applied to the cylinder chamber on the instrumentation air
feed/discharge port A .The air pressure is then applied to the piston 104 which moves
towards the cylinder chamber on the air feed discharge port B . At this time, the piston
rod 106 connected to the piston also moves in the same direction. This movement is
transferred to the stem through the connector 125 to open the value.
On the other hand, when air pressure is supplied from the air feed/discharge port B (cylinder
chamber on the air feed/discharge port A is in the state of atmospheric pressure), the valve
moves in the direction of closing.

7. Daily Inspection and Periodic Inspection

7-1. Daily inspection

! CAUTIONS
When carrying out daily inspection of this control valve, observe the cautions
given in 4-1, Preparations for operation.

If your control valve is important for the operation of your pipeline in which it is installed,
carry out daily inspection as follows.
• For prevention of malfunctions, check the instrument air inlet pipe connection for air
leakage.
• Check the gland packing and the gasket for fluid leakage. If fluid leakage from any of
them is detected, check the valve stem for damages. If the valve stem is found intact,
retighten the gland packing while checking the operating condition.
• If your control valve is equipped with a positioner, check to see if the valve operates
without hunting, and to see if the valve stem operates smoothly.
• When the control valve is operating, check to see if the control valve and its piping are
free of vibration.
If any defect not repairable soon on the spot should be detected by daily inspection, repair
it later when the plant can be shutdown, or contact KOSO Services.

15
7-2. Periodic inspection

! WARNING
• When carrying out periodic inspection, follow the warnings given in:
4-2.Operation 10. Disassembly and reassembly

! CAUTIONS
• When carrying out periodic inspection, observe the cautions given in:
3-4. .Piping and wiring 4-1. Preparations for operation
4-2. Operation 10. Disassembly and reassembly

7-2-1. Monthly or bimonthly inspection

Inspect all your control valves as follows.
• For prevention of malfunctions, check the instrument air inlet pipe connection for air
leakage.
• Check the gland packing and the gasket for fluid leakage. If fluid leakage from any of
them is detected, check the valve stem for damages. If the valve stem is found intact,
retighten the gland packing while checking the operating condition.
• If your control valve is equipped with a positioner, check to see if the valve operates
without hunting, and to see if the valve stem operates smoothly.
• When the control valve is operating, check to see if the control valve and its piping
are free of vibration.
If any defect not repairable soon on the spot should be detected by this periodic
inspection, repair it later when the plant can be shutdown, or contact KOSO Services.

16
7-2-2. Annual or biannual inspection
Inspect, confirm, lubricate and/or replace the following parts.
＊ This inspection should advisably be carried out by experienced KOSO service
engineers.

(1) Actuator
• Lubricate the inside of the cylinder and the guide of the piston rod.
KOSO recommended oil:
Standard use : Moly-Speed Grease No.0 or equal
(SUMIKO-Lubricant Co., Ltd.)
High-temperature use : Moly-Speed Grease No.0 or equal
(SUMIKO-Lubricant Co., Ltd.)
Low-temperature use : Molysil No.2 or equal
(SUMIKO-Lubricant Co., Ltd.)
• Check the bolts and nuts for damages and dimensional loss by corrosion.
Replace defective parts, if any, with new ones.

(2) Valve assembly

• Dismount the bonnet from the body in accordance with the valve disassembling
procedure. Check the valve parts for wear, tear and other damage. Replace
damaged parts, if any, with new ones.

17
8. Troubleshooting and Remedies
Symptom Possible Cause
• Air pressure supply too low
• Air supply piping clogged or
leaking
• Air leakage from between
cylinder and cylinder cover
• Air leakage from upper and
lower portions of actuator
output shaft
• No operation • Defective accessories:
(Operation too slow) Positioner, booster relay,
solenoid valve, lock valve, etc.
• Valve assembly or actuator out • Remove the connector, and
of order
• Manual operation handle is in a • Set the handle in the position of
manual operation position.
• Improper sensitivity of the
positioner
• Load fluctuations by controlling • Use a larger actuator.
fluid (Insufficient actuator
output)
• Unstable operation • Fluctuations of signals from the • Change controller setups, or
(Accompanied by controller
hunting) • Fluctuations in supply air
pressure
• Defective reducing valve
• Leak from valve seat • Insufficient output from the
actuator, or damaged seat ring.
• Damage to valve seat
• Leak from gland • Loosened nut, damaged valve
packing/gasket stem, or degraded or hardened
packing gasket.
18
Remedy
• Supply air pressure at a
specified level.
• Clean piping inside, further
tighten pipe connections, or
replace defective pipe.
• Retighten, or disassemble and
correct (or replace).
• Disassemble and replace O-ring.
• Try to apply air pressure directly
to the instrument air inlet of the
actuator instead of applying it
through the accessories. If this
operates the control valve
normally, inspect, and readjust
or replace defective accessories
(positioner, booster relay, etc.).
check the operation of the
actuator only. If the actuator
does not function properly,
disassemble and correct the
actuator. If the actuator is
properly functional, disassemble
and correct the valve assembly.
automatic operation noted in
Item 4-2 (1).
• Replace the capacitance spring,
following the instructions given
in the manual for the positioner.
check the signaling system.
• Recheck the pressure air supply
pipe diameter or replace.
• Repair or replace the reducing
valve.
• Check and adjust
instrumentation air pressure.
• Disassemble and correct the
valve seat (or replace parts if
necessary).
• Tighten loose nuts, or replace
packing gasket. Repair valve
stem surface, or replace.
9. Preparations for Disassembly

! WARNING
• Before disconnecting this control valve from the process piping for disassembly and
inspection purpose, and before setting about inspecting and repairing the inside of
the control valve, make certain that the pressure in the control valve is the
atmospheric pressure and that the temperature is not higher than 45°C.
• If your control valve is used for controlling a fluid powerfully poisonous to persons,
make certain in advance that the inside of the control valve has been thoroughly
cleaned, and then proceed to disassemble it.

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10. Disassembly and Reassembly
10-1 Separation of actuator from valve assembly

! WARNING
This control valve is heavy and therefore needs to be handled carefully and properly,
following the instructions given below. Failure to observe these instructions may
cause serious injuries on persons.
• On the flange connection type, it should be lifted using a lifting machine
conforming to Labor Safety/Sanitation law and the valve unit be fixed firmly on a
flat floor of work site before starting the work.
• On the weld connection type, choose a safe space and lift it using a lifting machine
conforming to the Labor Safety/Sanitation law before starting the work.
Follow the procedure given below.
• Set the instrumentation air feed/discharge ports ( A and B ) of the actuator in the
state of atmospheric pressure.
• Using a hexagon rod spanner, turn counterclockwise the hexagon socket head cap
screw 126 holding the connector 125 that is used to couple the stem of the control
valve with the output shaft of the actuator. Then, remove the bolt together with the
spring washer 127 . The connector and the stopper B 122 are also removed.
• Separation of yoke 101 from valve.
(1) Actuator (6315LA, 6320LA 6330LA) (Fig. 10-1)
Using a chisel with rectangular tip and a hammer, loosen and remove the yoke
nut 201 by applying impacts to the dent of the nut in counterclockwise direction.
Using a hexagon rod spanner, loosen the hexagon socket set screw 131 by turning
counterclockwise. The yoke is separated from the valve.
(2) Actuator (6345LA, 6360LA) (Fig. 10-2)
Loosen the hexagon bolt 203 and remove it together with the spring washer 204 .
The yoke is separated from the valve.

Actuator Actuator

Valve Valve
Fig. 10-1. Fig. 10-2.

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10-2 Disassembly of actuator

! WARNING
• Before starting the disassembling work, ensure that the cylinder chamber is at
the atmospheric pressure. Failure to observe this warning can cause injuries to
persons induced by compressed air.
• During the disassembling work, care should be taken not to drop disassembled
parts on your feet or not to pinch your hands or fingers to prevent serious
injuries.
• To wash and clean disassembled parts, be sure to put on a protective goggles.
Do not touch cleaning liquid with bare hands. Wear rubber gloves.

! CAUTIONS
• During the disassembling work, care should be taken not to flaw the inside of
the cylinder, the surface of the piston rod, the output axle surface of the air
pressure seal part, etc. It may cause malfunction.

(1) Removal of accessory devices

When accessory devices are mounted on the actuator, carefully remove the air piping
and electric wiring of accessory devices before disassembling the actuator. Then
remove the accessory devices from the actuator.

(2) Disassembly of actuator without manual operation mechanism

For removal, use the following procedures. For the encircled part numbers, refer to
Fig. 5-1.

• To facilitate reassembly, mark the position of the stopper A 121 , which has not
been disassembled, on the piston rod 106 , then loosen the hexagon socket set
screw 132 using a hexagon rod spanner and remove the stopper A.
• Loosen the hexagon bolt 109 holding the cylinder 105 , cylinder cover A 102
and cylinder cover B 103 , and remove it together with the spring washer 110 .
Cylinder cover B 103 , cylinder, O-ring 115 , 116 are removed.
• Using a special tool, remove the C-type retaining ring 120 and remove the split
ring retainer 114 , split ring 113 and piston 104 in that order from the piston rod.
Also, pull off the piston rod toward the yoke 101 .
• Loosen the hexagon bolt 111 and remove it together with the spring washer 112 .
The yoke and cylinder cover are separated.

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 • Remove O-ring 117 , dust seal 119 .
• Visually check the inside of the DU bush 107 . If it is not damaged, do not
disassemble it.
After disassembling, wipe each part thoroughly with dry cloth. If required, wash and
clean it with solvent and dry it thoroughly.
Check all the parts to see if they are damaged. If damaged, replace with new ones.

(3) Disassembly of actuator with top/side handle type manual operation mechanism
Follow the procedure given below. For the encircled part numbers, refer to Fig. 5-2.

(3-1) Removal of operation mechanism

• Loosen the hexagon bolt 353 holding the gear case 340 to the cylinder cover
A 102 , and remove it together with the spring washer 354 .
• Using the hoisting hole at the gear case, lift the manual operation mechanism
vertically, making sure that a bending force is not applied to the piston rod 106B .

(3-2) Disassembly of actuator main unit

• To disassemble the actuator main unit, follow the disassembling procedure for the
actuator without manual operation mechanism noted in the previous item 10-2 (2).
(3-3) Disassembly of manual operation mechanism
When disassembling the manual operation mechanism, remove the hand wheel lock
pin 362 and turn the hand wheel 348 . If it turns smoothly without unusual noise,
the manual operation mechanism need not be disassembled.

If it becomes necessary to disassemble it, use the following procedure.

•Remove the bellows 352 and turn the hand wheel clockwise until it comes to stop,
then remove the C-type stop ring 371 using a special tool.
• Loosen the hexagon bolt 357 and remove it together with the spring
washer 358 .The hand wheel can be disassembled by pulling it toward you.When
the small bevel gear 344 or the deep groove ball bearing 350 is defective, loosen
the hexagon nut 374 and remove it together with the spring washer 375 , then
remove the hand wheel.Next, remove the spring pin 361 and pull off the small
bevel gear toward the gear side.
• Loosen the hexagon bolt 355 and remove it together with the spring washer 356 .
Then remove the gear case cover 341 .,The thrust ball bearing 349 , sliding
key 368 , retaining plate A 369 , 370 , bevel gear assembly (large bevel
gear 343 , screw nut 346 ), drive shaft assembly, drive shaft 345 , stopper
nut 351 , and hexagon socket set screw 390 can be disassembled.
22
 • Using a hexagon rod spanner, loosen the hexagon socket set screw 390 and then
turn the stopper nut counter clockwise until it is removed.
• The engagement (left threads) of the drive shaft with the screw nut can be released
by turning them clockwise.
After disassembling, wipe each part thoroughly with dry cloth. If required, wash and
clean it with solvent and dry it thoroughly.
Check all the parts to see if they are damaged. If damaged, replace with new ones.
(4) Disassembly of actuator with top handle type manual operation mechanism
Follow the procedure given below. For the encircled part numbers, refer to Fig. 5-3.
(4-1) Removal of operation mechanism
• Loosen the hexagon bolt 353 holding the gear case 340 to the cylinder
coverA 102 , and remove it together with the spring washer 354 .
• Using the hoisting hole at the gear case, lift the manual operation mechanism
vertically, making sure that a bending force is not applied to the piston rod 106B .
(4-2) Disassembly of actuator main unit
• To disassemble the actuator main unit, follow the disassembling procedure for the
actuator without manual operation mechanism noted in the previous item 10-2 (2).
(4-3) Disassembly of manual operation mechanism
When disassembling the manual operation mechanism, turn the hand wheel 348 .
If it turns smoothly without unusual noise, the manual operation mechanism need not
be disassembled.
If it becomes necessary to disassemble it, use the following procedure.
•Remove the bellows 352 and turn the hand wheel clockwise until it comes to stop,
then remove the C-type retaining ring 363 using a special tool.
Remove the washer 364 and the hand wheel 348 .The key 367 is also removed.
• Loosen the hexagon bolt 355 and remove it together with the spring washer 356 .
Then remove the gear case cover 341 .
• Turn the screw nut 346 clockwise to remove it from the drive shaft 345 . The
thrust ball bearing 349 is also removed.
• Fix the gear case 340 . Using a plastic hammer, strike the drive shaft connecting
fork 372 from the mounting side to separate the drive shaft assembly from the
gear case. Next, loosen the cross recessed head screw 382 to remove the sliding
key 368 . The guide 347 is separated from the drive shaft.

After disassembling, wipe each part thoroughly with dry cloth. If required, wash and
clean it with solvent and dry it thoroughly. Check all the parts to see if they are
damaged. If worn or damaged, replace with new ones.

23
10-3. Disassembly of valve assembly

! WARNING
• Each part is heavy and cannot be carried with ease. Care should be taken not
to slip your hands to prevent serious injury.
• Always wear protective glasses whenever you work on the valve assembly to
remove its rust or repair its damaged parts by grinding.

! CAUTIONS
• On the flange connection type, care should be taken not to damage the gasket
of the flange.
• On the weld connection type, care should be taken not to drop disassembled
parts into piping.
• Do not put disassembled parts directly on a concrete, tiled or other hard floor.

To disassemble the valve unit, use the following procedure. For the encircled numbers,
refer to Fig. 5-4 and 5-5.
• Loosen and remove the hexagon nut 21 by turning it counterclockwise and then the
gland flange 17 , wiper 16 , and packing follower 15 to separate the gland
packing
• Loosen and remove the hexagon heavy nut 19 , by turning it counterclockwise and then
remove the bonnet 2 from the body 1 .
• Remove the plug assembly. If the plug assembly has been dismounted together with the
bonnet in the preceding step, pull out the plug assembly in the direction opposite to the
gland packing.

• Pull out the balance cylinder 8 , balnce seal 7 , multi hole Cage 4 , seat
ring 3 , and seat gasket 9 in this order from the valve body. Then remove the
bonnet gasket 11 and P/B gasket 10 in this condition. Don’t damage the cage
inside surface and the plug outside surface.
After completion of the disassembly, clean the parts with dry cloth. For parts to which
oil or solid matter in fluid is sticking, clean them with a solvent and then dry them with
dry air or nitrogen gas.
Make certain that the parts are free of wear and damage.

24
10-4. Reassembly of valve assembly
To reassemble the disassembled valve assembly, make the following preparations and
then reverse the valve assembly disassembling procedure stated in 10-3 above.
For the encircled numbers, refer to Figs. 5-4 and 5-5.

! CAUTIONS
Preparations for reassembly of valve assembly
• Do not place disassembled and cleaned parts on a concrete, tiled or other hard
floor.
• Prepare new replacing parts for the gland packing and gasket which are
expendables. Whenever you have disassembled the valve assembly,always
replace these expendables with new ones.
• For parts that have been found by inspection worn or otherwise damaged during
the disassembly, prepare new replacing parts. Particularly carefully inspect the
seat ring, the plug assembly and the balance cylinder. If not flawless, they can
be a cause of malfunction or leakage from the valve seat during operation after
reassembly.

(1) Mouting the balance seal

• Material : Teflon/SUS316
Mount the balance seal⑦on the balance cylinder⑧in the direction shown in Figs.
10-3 and 10-4

Over Plug Flow Under Plug Flow

Fig. 10-3 Fig. 10-4
• Material : Grafoil
Mount the balance seal⑦ on the balanc cylinder⑧ as shown in Figs. 10-5,10-6 and

10-7. Note that the number of spacers 26 varies with plug size.

25
 Fig.10-5. Fig.10-6. Fig.10-7
Plug size 1.25B Plug size 1.5B to 4B Plug size 6B and above
or smaller

(2) Tightening the gasket

! CAUTION
Fasten the bonnet evenly till reaching a torque value listed in Table 10-1.

After mounting the bonnet 2 in position, and while holding it in a condition

evenly and tightened by the hexagon nuts 19 , tentatively repeat moving up and
down the plug assembly to come into and out of contact with the valve seat several
times.
This tentative operation will complete centering the seat ring, the plug assembly, and
the bonnet. Then, using a torque wrench, permanently and evenly tighten the hexagon
nuts 19 to a torque value specified in Table 10-1, in a manner of tightening one
nut and then its diagonal nut.
Table 10-1 Gasket tightening torque

Bolt Size Tightening Torque (Nm)

M12 72
M14 120
M16 170
M20 330
M22 450
M24 570
M27 840
M30×3 1200
M33×3 1600
M36×3 2100
M39×3 2700
M42×3 3450
M45×3 4300
M48×3 5200
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(3) Mounting the gland packing

! CAUTIONS
• Mount the gland packing as shown in Figs. 10-8.
• Exercise care to avoid damaging the O.D., I.D., top and bottom surfaces
of the gland packing.
• For tightening the gland packing, use a tightening torque specified in
Table 10-2.

When mounting the square-formed gland packing, ensure that the cut joint of each
ring is 90° apart from that of its adjacent rings as shown in Fig. 10-8.

14
13

14
12
Fitting
position

: Teflon Fiber, P4519, P4504, P6315CL, P6710CH

: Teflon Fiber, P4519, P4504, P6315CL, P6610CH
Fig. 10-8

Table 10-2. Tightening torque square-formed gland packing

Packing material (Nm)
Stem
Body rating diameter TFE Fiber P4519 P4504 P6315CL P6610CH
(mm)
TFE Fiber P4519 P4504 P6315CL P6710CH
14 4.7

Upto class 17 5.4

600# 25 14

38 45

27
10-5. Reassembly of actuator
For assembling the actuator, follow the disassembling procedures (Item 10-2) in reverse
order. The following shows the main points of assembling work and precautions.

! CAUTIONS
Preparation before assembling actuator
• Do not put assembling parts directly on a hard floor such as concrete or tiled
floor.
• When handling heavy parts, be sure to use a proper hoisting machine. When
handling light parts, be careful not to drop them on your feet by slipping hands
or not to pinch your hands or fingers.
• During assembling work, be careful not to damage the inside of the cylinder,
the surface of the piston rod, and the surface of the output shaft of the air
pressure seal unit to prevent incorrect operation.
• Perform lubrication with grease referring to Item 7-2-2 “1-2 years check and
maintenance”.
• After disassembling, when the result of the check indicates worn or damaged
parts, they should be replaced with new ones.

10-6. Reassmbly of actuator and valve

After the following work is finished, assemble the actuator and the valve using the
disassembling procedure (Item 10-1) in reverse order.
For the encircled part numbers, refer to Figs. 5-1, 5-4, 10-1 and 10-2.
• Set the valve stem 6 in the state of closing.
• Assemble the yoke 101 as before and fix it in place.
On the actuator (6315LA, 6320LA, 6330LA), determine the position of the yoke and
tighten the hexagon socket set screw 131 . Then tighten the yoke nut 201 .
• Fix the stopper A 121 at the position marked before disassembling.
• While setting the stopper B 122 between the stopper A and the connector 125 in the
state of close contact with each other, make sure that the connector’s valve opening
indicator is set in the valve closing position of the division plate 128 , then tighten the
hexagon socket head cap screw 126 until the spring washer 127 makes a close
contact with the bolt.

10-7. Reassmbly of actuator accessories

After assembling the actuator to the valve, then carefully mount the accessories, and
carefully connect the air piping and electrical piping for the respective connection ports.

28
 11. Adjustment after Reassembly
On completion of the reassembly, check the performance as follows. If the performance is
defective, disassemble the unit, find the cause of the defect, and reassemble it again.
• While applying air pressure at a specified level to the actuator, make sure that it operates
smoothly at correct stroke. When the stroke is incorrect, the aforementioned connector is
defective and needs to be re-adjusted.
When the stroke is insufficient, reduce the clearance between the piston rod and the stem.
When it is too large, broaden the clearance between the piston rod and the stem.
• Perform the leak tests on the gasket and gland packing (it should be free from leak).
• Check to see if the leak rate of the valve seat is within the specified limit.
• Check to see if the hysteresis and the linearity are within the respective specified limit.
For reinstallation of the reassembled control valve in the piping, follow the procedure in
Section 3, Installation.

12. Disposal of Product or Parts

In districts were the disposal of products or parts is undertaken in accordance with an act for
the “disposal and cleanup of wastes” by a local public body or by industrial waste disposers
authorized by the local governor, the disposal of this unit or its parts must be entrusted to such
body.

! CAUTION
• Do not incinerate the tetrafluoro-resin gland packing and the seat ring.
If incinerated, they will be decomposed at high temperatures to emit poisonous
fluoride gases, the inhalation of which is harmful to health.

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13. Maintenance Parts
Maintenance parts or expendables for replacing worn or damaged parts are available by
ordering to any local distributors of our representatives listed below.

WORLD-WIDE NETWORK (Sales, Manufacturing, Services)

Nihon Koso Co., Ltd., Tokyo, Japan Tel. (81) 3-5202-4300 Fax. (81) 3-5202-4301
Paris Office Tel. (33) 1-73-75-23-1 Fax. (33) 1-73-75-23-1
Moscow Office Tel. (7) 495-775-8531 Fax. (7) 495-787-2758
Dubai branch Tel. (971) 4-881-3090 Fax. (971) 4-881-5090
Beijing Office Tel. (86) 10-5877-2863 Fax. (86) 10-5877-2867
Koso M-Mac International Inc., CA, U.S.A. Tel. (1) 661-942-4499 Fax. (1) 661-942-0999
Koso America Inc. Boston, U.S.A Tel. (1) 508-584-1199 Fax. (1) 508-584-2525
Pacific Seismic Products.Inc., CA, U.S.A. Tel. (1) 661-942-4499 Fax (1) 661-942-0999
Koso Kent Introl. Ltd., U.K. Tel. (44) 0-1484-710311 Fax. (44) 0-1484-407407
Koso Control Engineering (Wuxi) Co., Ltd., China Tel. (86) 510-85129961 Fax. (86) 510-85127827
Wuxi Koso Fluid Control Co., Ltd., China Tel. (86) 510-85101567 Fax. (86) 510-85105339
Wuxi Koso Valve Casting Co., Ltd., China Tel. (86) 510-85117433 Fax. (86) 510-85117433
Hangzhou Hangyang KOSO P & V Co., Ltd. Tel. (86) 571-85869508 Fax. (86) 571-85343203
Koso-AACI (Anshan) Co., Ltd., China Tel. (86) 412-8812686 Fax. (86) 412-8814582
Korea Koso Co., Ltd., Seoul, Korea Tel. (82) 2-539-9011 Fax. (82) 2-566-5119
Korea Koso Engineering Co., Ltd., Seoul, Korea Tel. (82) 2-539-9018 Fax. (82) 2-566-5119
Koso Controls Asia Pte Ltd., Singapore Tel. (65) 67472722 Fax. (65) 67467677
Kent Introl Private Ltd., India Tel. (91) 253-2383111 Fax. (91) 253-2384413
Koso Fluid Controls (Private) Ltd., India Tel. (91) 491-2566047 Fax. (91) 491-2567142

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