600 KN Towing Winch Manual

600KN HYDRAULIC TOWING WINCH
OPERATION INSTRUCTION
OPERATION
INSTRUCTION
Compiled by:
Jing Wang
Checked by:
MinFang Zhu
Verified by:
Yi Chen
Chongqing Lange Machinery Group Co., Ltd.
PAGE 1 / 13
CONTENTS
1. General
2. Main Technical Features
3. Structure Instruction
4. Operation and Use Regulations
5. Maintenance
6. Assembly and Disassembly
7. Towing Winch Operation and Use Regulations
8. Electrical Component
9. Operation Instructions
10. Drawing and main structure
15
11. Electric part drawing
27
12. Marine proportional valve Service Manual
13. Swash-plate type Axial piston pump Service Manual
43
14. Hydraulic motors Maintenance Manual
53
PAGE 2 / 13
1. General
1.1 This Operation Instruction is applicable to 600 KN Hydraulic Towing Winch.
2. Main Technical Features
2.1 Drum Part:
Drum diameter
770mm
Drum load (2st Layer)
600KN
Holding load (2st Layer)
1800KN
Mooring speed (2st Layer)
0-5m/min
Light load speed: load 150KN
0-18m/min (2st Layer)
Wire rope diameter
48mm
Wire rope standard
6X36SW+IWR+48-2150
Rope capacity
750m
Motor type
HMC200
3. Structure Instruction
This Hydraulic Towing Winch consists of three parts: mechanical part, hydraulic
part and electrical part, with independent hydraulic pump unit. Following is brief
structure and operating principle of the main parts of the mechanical and hydraulic
parts.
3.1 Mechanical Part

Mechanical part mainly consists of drum shaft device, wall shelf, foundation, clutch
device, brake and driving device etc.
3.1.1
Drum Shaft Device
Drum shaft mainly consists of drum, clutch, bearing axle, bearing, warping drum,
and gear wheel etc.
Wrapping drum is installed at the outermost side of the shaft. Sliding bush drum
on the shaft, clutch and shaft are coupled hexagonally. While wrapping, push clutch
handle to make jaws of clutch and jaws of drum engage or disengage, thereby
fulfilling action of drawing and releasing cable. Bull gear on the drum shaft engages
PAGE 3 / 13
with pinion gear fixed on hydraulic motor.

3.1.2
Foundation
The foundation mainly consists of basement, bracket, bushings etc. Fixed on ship
hull, the foundation is used for supporting drum shaft device and clutch device.
3.1.3
Wall Shelf
The wall shelf consists of wall shelf and bearing, to support bearing axle device,
it is connected with fixing bolt and foundation.

3.1.4
Clutch Device
The clutch device is handle-shift type. The handle and shift are welded together.
Bearings are mounted on the brackets. T-shape pin on shift plugs in annular recess of
jaw clutch. While pushing the handle, clutch is moving, to make the jaws of clutch
and jaws of drum engage or disengage. There is an orientating pin on the handle to
avoid displacement of clutch.
3.1.5
Brake Device
The hydraulic towing winch adopts belt brake, the brake device is mainly
composed of two and a half brake bandhydraulic cylinderconnecting rodleverage
shaftpinpin shaft sensor ,brake etc. Brake band consists of steel belt, non-asbestos
woven brake band, two and a half brake band via the ear plate at one end with a pin
connected together, the other end of the steel belt 1 through the pin shaft type sensor
with brake bracket installation, steel belt 2 through the pin shaft connected to the
connecting rod, shaft is installed on the brake bracket and connected to the connecting
rod and lever, oil cylinder through the pin shaft is installed on the lever. Through the
oil cylinder inlet and the oil return control lever in order to realize the brakes brake
tight and loosen, pin type sensor in this process by giving signals to display stress
distribution on the control panel.
3.1.6
Driving device
It composed with hydraulic motor, gear case, small gear. The hydraulic motor is
fixed in the gear case, by the small gear which is installed on the oil motor output
shaft and the shaft installed in the load on the big gear meshing power output.
3.1.7
Rope guide
PAGE 4 / 13
Rope around by stent assembly, double guide screw, shaft, rope, chain wheel,
hand wheel, etc. Rope frame installed on the double guide screw and shaft, the chain
wheel is installed on the double guide screw, double guide screw and shaft fixed
installation on the left and right bracket assembly, chain wheel on the drum shaft and
double guide screw on the sprocket chain transmission to drive the double guide
screw rotation, so that the rope to rope frame to move around. Rope installed on a
hand wheel, when the rope is error can be adjusted by hand wheel.
3.1.8
Fair-lead
Fair-lead s composed of about bracket and mooring rod, mooring rod is
installed on the bracket around, in the device when you receive cable can be adjusted
through the fairlead cable out of the line height.
3.2 Hydraulic Pump Unit
Hydraulic pump unit including: oil pump, diesel engine, control valve, cooler
and oil tank.
3.2.1
Hydraulic pump
Hydraulic pump is constant-power controlled axial plunger pump. Pressure oil

flows out from outlet of pump, through manual proportional combined valve,
hydraulic motor, radiator, then back to oil tank to make an open return circuit. While
load changing, hydraulic pump displacement approximately varies as constant power.
That makes it feasible to take full use of motor output to prevent motor overloading.
3.2.2
Oil Tank
Oil tank is design and manufactured by shipyard.

3.2.3
Cooler
In condition of oil heat because of working at high condition temperature or

working for a long period, use coolant to keep oil temperature no more than 60 .
3.2.4
Operating Board
Operating board, which is used for operating mooring winch to direction reserving
and speed regulating, is located near main deck mooring winch. It is composed of
manual proportional combined valve and foundation. Manual proportional combined
valve is flow control three-position four-way reversal valve with pressurePAGE 5 / 13
compensation overflow device inside. It has fine capacity of direction reserving and
speed regulation. Pushing handle to certain angle according to required speed can
regulate speed.
Operation and Use Regulations
4.1 Attention Before Using

(1) Check lubrication of bearings and exposed gear. Ensure each motional part is
lubricated well.
(2) Check oil level of oil tank, and ensure hydraulic oil reaches specified level.
(3) Check whether there is any obstruction next to mooring winch.
(4) Check whether clutch is at correct position.
(5) Check safety and reliability of brake rigging.
(6) Check whether fixed bolts of each parts of mooring winch are loose.
4.2 Operating Hydraulic Towing Winch

4.2.1
Main Drum and Vice Drum
(1) Start hydraulic pump motor.

(2) Engage drum clutch.
(3) Push handle to wrap cable.
(4) When wrapping finished, push handle to mid-position.
(5) Shut down hydraulic pump motor, and brake drum brake rigging tightly.
(Reserve cable at least 4 to 5 circles at first layer around drum for safety while
wrapping)
4.2.2
Main and vice drum wrapping
(1) Disengage drum clutch, then brake the brake rigging tightly.
(2) Roll cable around the wrapping drum for 4 to 5 circles.
(3) Start hydraulic pump motor. (operating handle is at mid-position.)
(4) Push handle to wrap cable.
(5) After wrapping finished, push handle to mid-position.
(6) Shut down diesel engine.
PAGE 6 / 13
Maintenance
5.1 Mooring Winch should run in well lubricating condition to decrease abrasion of
friction surfaces of each motional part and prolong service life of machine.
5.1.1
Every grease cup should be full of grease. Fill oil to every friction surface
periodically, then run mooring winch idly for a moment to ensure grease evenly
distribute to each friction surface.
5.1.2
Contact surface of exposed gear should be greased periodically.
5.1.3
All non-machined surfaces of mooring winch should keep clean. Exposed
surfaces should be painted often to prevent rusting.

5.1.4
Often check whether there is any failure of every part, and whether fixed
bolts are loose.
5.2 Maintenance of Operating Valve

5.2.1
Cover the operating valve with protective covering when it is not in use.
5.2.2
Exposed surfaces of operating valve should be painted periodically to prevent
rusting.
5.3 Protection of Hydraulic System

5.3.1
Make sure working oil of hydraulic system is clean. Observe and change oil
periodically. Observe every three months, and change every year. If oil goes bad
or oil viscosity is not conformed to requirement, change oil immediately. Clean
pipelines and oil tank while changing oil. Oil must go through filter screen of oil
tank while filling.
5.3.2
Hydraulic oil is YB-N68 anti-attrition hydraulic oil. Considering oil viscosity
fluctuated great adapting to temperature, exchange oil adapting to seasonal

variations and latitude variation of navigational zones.
5.3.3
Observe and clean oil absorbing filter screen and oil filter cartridge
periodically.
5.3.4
Observe oil level of oil tank periodically, and refill leaked oil in time.
PAGE 7 / 13
5.3.5
Observe hydraulic system while running mooring winch. Ensure there is no
abnormal heat, noise and leakage. Obviate immediately if something is failed.

5.3.6
Pay attention to the oil temperature of oil tank. Make sure oil temperature
range is from -20 to +50, and maximum is not higher than 60.
5.3.7
Even though do not run mooring winch for a long period, start hydraulic
pump unit periodically. Run mooring idly for about 10 min, and no less than once
every month.
5.4 If Mooring Winch is disassembled from deck during general ship overhauled,
hydraulic pump, hydraulic motor and valve should be full of oil to avoid
components rusting. Joints are plugged with cork stoppers or metal screw plugs.
Brush apt-rusty surface with anti-rusting oil. Store all parts in dry room.
Assembly and Disassembly
6.1 Disassembling Procedure of Mooring Winch

6.1.1
Drain hydraulic oil inside oil tank and pipelines.
6.1.2
Disassemble all hydraulic pipelines.
6.1.3
Disassemble rope guide and fair lead.
6.1.4
Disassemble gear covering.
6.1.5
Disassemble actuator.
6.1.6
Disassemble brake rigging.
6.1.7
Disassemble clutch device.
6.1.8
Disassemble bearing cover on the supporter, then take the drum shaft device
off.
6.1.9
Disassemble hydraulic pump unit.
6.1.10
Disassemble operating valve.
Keep on disassemble other parts continuously if necessary.
6.2 Assembly
Assembling procedure is contrary to the disassembling procedure.
PAGE 8 / 13
7. Towing winch Operation and Use Regulations

7.1Towing machine is a kind of special towing equipment, used for cable release,
towing without self-propelled ability of ships and offshore facilities (such as barge,
floating crane, floating dock, dredge and drilling platforms, etc.) and losing the ability
to self-propelled ship, are some of the key equipments on the civilian and military
vessel.
Towing winch is composed by drive device, roll device, brake device, rope device,
clutch device and foundation. According to the different way of driving power,
Towing winch can be divided into towing winch steam engine, diesel engine towing
winch, electric towing winch and hydraulic towing winch type, etc. According to the
different operation control mode can be divided into automatic towing winch and the
automatic towing winch. Non-automatic towing winch similar to ordinary mooring
winch, while towing machine work in a special law. Non-automatic towing winch
usually use manual operation to control the release of the cable, higher requirements
for operators. Towing machine can automatically detect the length of the cable tension
and release, according to the change of the tension and the cable release length
automatically adjust the cable release.
7.2 Ship towing winch device briefly installation process is as follows

7.2.1 Towing winch base production of precision machining and welding control
First of all, according to the size of the gravity center of gravity and force of towing
winch, determine the form of a good base, the thickness of the base panel as well as
the corresponding parts of the hull structure, making the base of the construction
drawingsAccording to construction drawings, field production base, because of the
towing winch base area is larger, need to develop a base assembly welding precision
control plan, to ensure the flatness of the base panel, can be carried out when
necessary base panel on the surface of the whole machine tool processingBase
production after completion of inspection on the ship welding, also we will strictly
follow the base board welding process, after checking the size and structure of
PAGE 9 / 13
reinforcing the step will base welding on the boat, strict control of welding
deformation in the process, to ensure that the base installation precision meet the
requirements.
7.2.2 Towing winch lifting installation
Because the towing winch itself volume is larger and the weight is very big
According to equipment manufacturers to provide equipment center of gravity and
lifting point location, lifting scheme, detailed with experienced worker, operation to
ensure the safety of the equipment hoisting. For towing winch dragging force is huge,
so the installation precision is higher also. In order to increase the contact area
between device and the base panel, make equipment fiasco feet and uniform structure
between stress, so that the equipment running smoothly, increase the service life, the
form of water epoxy resin can be used as adjusting shim to install. Epoxy resin
solidification shrinkage after 1/1000, hardness is higher, and stand with device
interface is 100%, because of its safety, quick, efficient, large equipment installation
in the process of application on the ship already more and more widely. Torque screw
down the bolt installation in accordance with the relevant provisions.
After installed the towing winch, According to the manufacturer to provide the
working data pipeline and cable laying, Upon the acceptance of laying out according
to the test outline procedures for towing winch function test.
7.2.3 Towing winch related equipment function test
Start the towing winch servo hydraulic pump to provide towing winch servo oil,
Towing winch brake, clutch, and row for cable, sprocket, chain guide, the function of
the horizontal cylinder test, Check the reliability of the transformation between the
main pump and standby pump.
7.2.4 Text and check
(1) Check all the moving parts for abnormal fever, tap on a phenomenon
(2) Check if there is a leak in the hydraulic system
(3) Check the performance of the diesel engine
(4) Check the electrical control equipment and the gear speed and electromagnetic
device work
PAGE 10 / 13
(5) Check and adjust the overload protection device, according to the technical
requirements to adjust the relief valve opening pressure of hydraulic system
(6) After test, check each mechanical parts in detail
7.2.5 Text record
(1) Record oil pump working pressure, oil pump and oil motor speed
(2) Record the diesel engine starting current, working current, volt meter speed
(3) Record of diesel engine operation is normal
(4) Record when towing winch tests of power and speed of factors
7.2.6 Do emergency stop and emergency towing winch release test
7.2.7Provide the factory test report of the relief valve of hydraulic pump, check the
opening pressure
7.2.8 Do the towing winch system emergency alarm function test
8. Electrical Parts Summary

8.1 Display
A: Cable, speed indicator
B: Diesel engine fault signal, the oil block, oil high temperature, low oil level, Low
oil level alarm indication, sound-light alarm and sound damping button.
C: Cable length, speed, over hoist and over release and level display.
8.2 Main and vice drum revolve
A: Vice drum do not working when main drum working, when main drum working,
just the opposite.
B: When operating the control panel, operating floor on the side of the machine do not
working, in turn, on the other side.
C: Low speed when hosting, low speed or fast speed when releasing, fast or low
according to the working requirement. Pay attention to the working state when fast
speed.
D: Open the operating handle in WHC (or operating deck in the side of machine),
open a brake cylinder (main or vice drum), close the clutch (main or vice drum).
PAGE 11 / 13
Operating the WHC.: open the brake cylinder, clutch(close) fast speed . low speed,
touch screen interface display.
E: When you hoist cable to reel with 100 m pre-alarm, When you hoist cable to reel
with 50 m downtime.
When you release cable to reel with 650m pre-alarm, When you release cable to reel
with 700m downtime.
8.3 Emergency Release

A Press the 'emergency release "button when in dangerous situations, In the PLC
instruction after, Emergency release electric solenoid valve,(when the brake is open
and clutch is closed )
The main drum in 1 secondshoist and release round, When the main drum clutch
disengaged, main drum started emergency release, to put the wire rope.
B: In the condition of main drum hoisting, pull tension1800KN PLC in the tension
sensor signal, issuing commandsEmergency release electric solenoid valve(when the
brake is open and clutch is closed )
8.4 Constant tension
A: Constant work to give priority to drum up force is special, deputy drum without
this feature
B: Work in open constant tension, the tension < 550 kn, the drum automatic line, in
pull > 600 kn automatically when the cable.
C: Constant tension work when the clutch is closed, open automatically brake
8.5 Beyond
A: This button to use in the cable or cable discharge
B: In when you receive cable, cable head left the tug 50 m has stopped to receive line,
to press the "beyond" can receive cable to the bow.
9. Operation Instructions
9.1 Oil pump, oil in motor
9.2 After all the overflow valve pressure switch to the lowest, open the oil pump,
PAGE 12 / 13
adjust the relief valve set pressure

9.3 Check the clutch and brake open and close action, hoist and release cable direction
and speed of the motor speed conversion is normal, then close the oil pump,
accumulator is used to realize the above work.
9.4 Will brake switch to nature, Closed the main and vice drum clutch respectively.
Low speed, oil in the gear and all of the turn and slide parts.
9.5 Idling the machine, rotating 15min in the positive and negative direction,
Determine the same ring, fever and adverse conditions such as oil, Row for cable to
pressure side line board, tighten the cable on the drum, Pack up the cable, check if the
cable is normal
9.6 Respectively according to the rated load test of brake the sensors under the rated
load working state is normal
9.7 Each function all meet, boot standard everything is normal, the operator can be
used on
PAGE 13 / 13
600KN
600KN
PAGE 1 / 8
600KN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
15
11.
27
12.
13.
43
14.
53
PAGE 2 / 8
600KN
1
1.1 600KN
2
2.1
770mm
600KN
1800KN
0~5m/min
150KN 0~18m/min
48mm
6X36SW+IWR+48-2150
750m
HMC200
3
3.1
3.1.1
3.1.2
3.1.3
3.1.4
T
3.1.5
1 2
PAGE 3 / 8
600KN
3.1.6
3.1.7
3.1.8
3.2
3.2.1
3.2.2
3.2.3
65C
3.2.4
4
4.1
a.
b.
c.
d.
e.
f.
PAGE 4 / 8
600KN
4.2
4.2.1
4.2.1
1
2
3
4
5
4~5
4.2.2
1
2 4~5
3
4
5
6
5
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.2
5.2.1
5.2.2
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6 -10~+60C 65C

5.3.7 10min
5.4
PAGE 5 / 8
600KN
6
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.1.9
6.1.10
6.2
7
7.1
()
7.2
7.2.1
7.2.2
PAGE 6 / 8
600KN
1/1000
100%
7.2.3
7.2.4
(1)
(2)
(3)
(4)
(5)
(6)
7.2.5
(1)
(2)
(3)
(4)
7.2.6
7.2.7
7.2.8
8.
8.1
a
b
c
8.2
a
b
e 100m 50m
PAGE 7 / 8
600KN
650m 700m
8.3
a PLC
b 1800KN PLC
8.4
a
b550KN 600KN
c
8.5
a
b 50m
9.
9.1
9.2
9.3
9.4
9.5 15
9.6
9.7
PAGE 8 / 8
600KN
600KN Hydraulic towing winch
General and main structure
HSGL 70/35-30-350
Oil cylinder dismounting procedure
1.
1
Release the oil cylinder pressure before dismantling, turn the oil mouth
to the bottom and drain the hydraulic oil thoroughly, as figure (1).
1
2
2
Stretch the piston rod to the longest position. Catch the guide sleeve
by the hook spanner to rotate the neck anticlockwise to the bottom. After
the guide sleeve and cylinder tube separated, pull the ear rings on two
sides of the oil cylinder by manpower to separate cylinder tube and piston
slowly, as figure (2).
2
3.
Take down piston , use drill on tight set screw to drill hole. Drill
hole until the set screw worn out. Stop to check the wear pattern of set
screw during drilling. Find below figure, the left side means the set screw
was worn out, it means the piston is released. Rotate piston
anticlockwise to take it off, as figure (3).
3
4.4
Take off the guide sleeve from the piston (need copper bar to beat),
as figure (4).
4
5.
Take off the seals needed to be replaced by hand. Remember the mounting
direction of the seals. The oil cylinder is finished dismantling.
6.
Put in the seals needed to be replaced and clean the surface by the
air-laid paper.
7.
Clean the piston rod surface by the air-laid paper after finishing
replacement. Mount the guide sleeve from dismantling port (Please justify
the direction during assembling to avoid scoring the seals).
8.5
After tight the piston and piston rod, tap from left side and screw
the set screw, as figure (5). And knock on the thread mouth to deformation
by the anvil so that the set screw will not get loose.
5
9. 5
Put the condition like figure (5) into cylinder tube. Catch the guide
sleeve by the hook spanner to rotate the neck clockwise tightly. The oil
cylinder is finished assembling.
600KN
600KN Hydraulic towing winch
Electric Part

Hydranor
6MBA
Marine proportional valve
Service Manual
HYDRANOR
Spare Part List 6MBA-320-37-7G-BE

HYDRANOR
Parts drawing
NO OFF
DIM. DRAW.
101917 Rev.0
SPARE PART
DRAW.
P
1
SPECIFICATION
PA
MODULATING ELEMENT
LRJC-XDN
PILOT VALVE
12
PB
PRESSURE VALVE
RPCC-LQN-HT182
NOZZLE
10
NOZZLE 0.6
411178
49
PLUG
1/8" BSPP VSTI-R
PC
SHUTTLE VALVE
48
PLUG
1/4" BSPP VSTI-R
67
SHUTTLE VALVE
WVE-R-1/4" BSPP
24
THROTTLE SCREW
404932A
29
O-RING
6.07 x 1.78 SHORE 70
30
CAP NUT
M8 DIN 1587 A4
38
NUT
M8 DIN 439B A4
THROTTLE VALVE
COUNTERBALANCE VALVE
SPOOL
303120
COVER
303121
SCREW
422971
13
SPRING
418686
15
SPRING SEAT
421205
28
CAP NUT
419936
37
NUT
422969
45
O-RING
59.50 x 3.00 SHORE 70
54
DOWTY
PPM-16
62
BALL, STEEL
RB 10
70
PISTON
422232B
CA
CHECK VALVE
SPRING
402852
25
SPRING SEAT
402920
26
PISTON
400961A
46
PLUG
1 1/2" BSPP VSTI-R
Date: 03.05.2005. Rev.0
A/S HYDRANOR N-3600 KONGSBERG

DOK 9001.063
NO OFF
COMPENSATOR
3
DESCRIPTION
RECOMMENDED SPARE PARTS
HIGH QUALITY MARINE HYDRAULICS

Page 2 of 3
4-25531
03890327-E
K3VL

Swash-plate type Axial piston pump

Service Manual

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XV-2P/04
XV-2P/06
XV-2P/09
XV-2P/11
XV-2P/14
XV-2P/17
XV-2P/19
XV-2P/22
XV-2P/26
XV-2P/30
XV-2P/34
XV-2P/40
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3EDU
3EDU
4,20
6,00
8,40
10,80
14,40
16,80
19,20
22,80
26,20
30,00
34,20
39,60
260
260
260
260
250
230
210
200
170
160
150
140
300
300
300
300
290
270
250
240
210
200
190
180
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X
X
X
X
X
X
X
X
X
X
X
X
2
2
2
2
2
2
2
2
2
2
2
2
P
P
P
P
P
P
P
P
P
P
P
P
41 41
43 41
45 41
47 41
49 41
51 41
53 41
55 41
57 41
59 41
61 41
63 41
F
F
F
F
F
F
F
F
F
F
F
F
S
S
S
S
S
S
S
S
S
S
S
S
5LJKWURWDWLRQ
R
R
R
R
R
R
R
R
R
S
S
S
A
A
A
A
A
A
A
A
A
A
A
A
X
X
X
X
X
X
X
X
X
X
X
X
2
2
2
2
2
2
2
2
2
2
2
2
P
P
P
P
P
P
P
P
P
P
P
P
41 42
43 42
45 42
47 42
49 42
51 42
53 42
55 42
57 42
59 42
61 42
63 42
F
F
F
F
F
F
F
F
F
F
F
F
S
S
S
S
S
S
S
S
S
S
S
S
R
R
R
R
R
R
R
R
R
S
S
S
A
A
A
A
A
A
A
A
A
A
A
A
P1) Max. working pressure - P3) Max. peak pressure

For heavy-duty applications, it is recommended to check the admissible torque of the shaft
Dimensions table
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PP
PP
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XV-2P/04
XV-2P/06
XV-2P/09
XV-2P/11
XV-2P/14
XV-2P/17
XV-2P/19
XV-2P/22
XV-2P/26
XV-2P/30
XV-2P/34
XV-2P/40
2,330
2,430
2,530
2,630
2,730
2,830
2,930
3,180
3,280
3,530
3,730
3,930
89,7
92,7
96,7
100,7
106,7
110,7
114,7
120,7
124,7
132,7
139,7
148,7
41,1
41,1
43,1
47,5
47,5
47,5
47,5
55,0
55,0
63,2
63,2
63,2
79,7
82,7
86,7
90,7
96,7
100,7
104,7
110,7
114,7
122,7
129,7
138,7
'
20
20
20
20
20
20
20
20
20
20
20
20
40
40
40
40
40
40
40
40
40
40
40
40
'
M6x1
M6x2
M6x3
M6x4
M6x5
M6x6
M6x7
M6x8
M6x9
M6x10
M6x11
M6x12
15
15
15
15
15
15
15
15
15
20
20
20
35
35
35
35
35
35
35
35
35
40
40
40
,1
287
2
*
'
(
)
,1287
287
,1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
T.1 = 5458.9 [Nm] - screw tightening torque M10

T.3 = 40 [Nm] - torque wrench setting 19
T.2 = 233.2 [Nm] - admissible shaft torque (N.B. When choosing a shaft, always check the admissible torque).
XP217
Vivoil Oleodinamica Vivolo s.r.l. - Sole Shareholder Company - via Leone Ginzburg 2-4 40054 Budrio (BO) Italy tel: +39 051 803689 fax: +39 051 800061
www.vivoil.com - english
30/06/2008
60

+
Testo5:
80 FLANGE
Left rotation
Shaft
Testo5:
CI001 - Parallel
41
Cover
Left rotation
Right rotation
42
Right rotation
CI002 - Parallel
T.2 = 44.1 [Nm]
T.2 = 67.5 [Nm]
CO001 - Tapered
CO002 - Tapered
T.2 = 233.2 [Nm]
T.2 = 233.2 [Nm]
SCF03 - Splined
T.2 = 86.1 [Nm]
Displacement
Standard bodies
7<3(
&2'(
'LVSODFHPHQWFPUHY
XV-2P/04
XV-2P/06
XV-2P/09
XV-2P/11
XV-2P/14
XV-2P/17
XV-2P/19
XV-2P/22
XV-2P/26
XV-2P/30
XV-2P/34
XV-2P/40
41
43
45
47
49
51
53
55
57
59
61
63
04
06
09
11
14
17
19
22
26
30
34
40
6WDQGDUGWKUHDGV
O-O
O-O
O-O
O-O
P-O
P-O
P-O
P-O
Q-P
Q-P
Q-P
Q-P
S-R
S-R
S-R
S-R
S-R
S-R
S-R
S-R
S-R
S-S
S-S
S-S
B-B
B-B
B-B
B-B
C-B
C-B
C-B
C-B
D-C
D-C
D-C
D-C
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
N
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Internal drainage
O
External drainage
Table showing standard flange and thread

combinations available in stock
Body (threads/flanges)
XP217
30/06/2008
61

/"/&"
2,+ !" ("#
X 2 P 51 52 I S R A
Series
Group
Category
Displacement
Flange
Shaft
IN
Body
OUT
Cover
X
2
P
51
52
I
S
R
A

0-)(5( :=74;
),%) -%->?@A+?-)(5B%@0@1$/3
%%-<

/-%-<-

$0
Technical data table

7<3(
'LVSODFHPHQW
XV-2P/04
XV-2P/06
XV-2P/09
XV-2P/11
XV-2P/14
XV-2P/17
XV-2P/19
XV-2P/22
XV-2P/26
XV-2P/30
XV-2P/34
XV-2P/40
0D[3UHVVXUH
&2'(
FPUHY
3EDU
3EDU
4,20
6,00
8,40
10,80
14,40
16,80
19,20
22,80
26,20
30,00
34,20
39,60
260
260
260
260
250
230
210
200
170
160
150
140
300
300
300
300
290
270
250
240
210
200
190
180
/HIWURWDWLRQ
X
X
X
X
X
X
X
X
X
X
X
X
2
2
2
2
2
2
2
2
2
2
2
2
P
P
P
P
P
P
P
P
P
P
P
P
41 51
43 51
45 51
47 51
49 51
51 51
53 51
55 51
57 51
59 51
61 51
63 51
I
I
I
I
I
I
I
I
I
I
I
I
S
S
S
S
S
S
S
S
S
S
S
S
5LJKWURWDWLRQ
R
R
R
R
R
R
R
R
R
S
S
S
A
A
A
A
A
A
A
A
A
A
A
A
X
X
X
X
X
X
X
X
X
X
X
X
2
2
2
2
2
2
2
2
2
2
2
2
P
P
P
P
P
P
P
P
P
P
P
P
41 52
43 52
45 52
47 52
49 52
51 52
53 52
55 52
57 52
59 52
61 52
63 52
I
I
I
I
I
I
I
I
I
I
I
I
S
S
S
S
S
S
S
S
S
S
S
S
R
R
R
R
R
R
R
R
R
S
S
S
A
A
A
A
A
A
A
A
A
A
A
A
P1) Max. working pressure - P3) Max. peak pressure

For heavy-duty applications, it is recommended to check the admissible torque of the shaft
Dimensions table
7<3(
:HLJKW
&
NJ
PP
PP
PP
XV-2P/04
XV-2P/06
XV-2P/09
XV-2P/11
XV-2P/14
XV-2P/17
XV-2P/19
XV-2P/22
XV-2P/26
XV-2P/30
XV-2P/34
XV-2P/40
2,280
2,380
2,480
2,580
2,780
2,880
2,980
3,130
3,230
3,480
3,680
3,880
88,0
91,0
95,0
99,0
105,0
109,0
113,0
119,0
123,0
131,0
138,0
147,0
39,4
39,4
41,4
45,8
45,8
45,8
45,8
53,3
53,3
61,5
61,5
61,5
78,0
81,0
85,0
89,0
95,0
99,0
103,0
109,0
113,0
121,0
128,0
137,0
'
20
20
20
20
20
20
20
20
20
20
20
20
40
40
40
40
40
40
40
40
40
40
40
40
'
M6x1
M6x2
M6x3
M6x4
M6x5
M6x6
M6x7
M6x8
M6x9
M6x10
M6x11
M6x12
15
15
15
15
15
15
15
15
15
20
20
20
35
35
35
35
35
35
35
35
35
40
40
40
,1
287
2
*
'
(
)
,1287
287
,1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
M6x1
T.1 = 5458.9 [Nm] - screw tightening torque M10

T.2 = 67.1 [Nm] - admissible shaft torque (N.B. When choosing a shaft, always check the admissible torque).
XP219
30/06/2008
62

+'&
Testo5:
82.5 FLANGE "SAE A"
Left rotation
Shaft
Testo5:
CI001 - Parallel
51
52
53
Cover
Left rotation
Right rotation
54
Right rotation
CI002 - Parallel
T.2 = 44.1 [Nm]
T.2 = 67.5 [Nm]
CO001 - Tapered
CO002 - Tapered
T.2 = 233.2 [Nm]
T.2 = 233.2 [Nm]
SCF04 - Splined
T.2 = 67.1 [Nm]
Displacement
Standard bodies
7<3(
&2'(
'LVSODFHPHQWFPUHY
XV-2P/04
XV-2P/06
XV-2P/09
XV-2P/11
XV-2P/14
XV-2P/17
XV-2P/19
XV-2P/22
XV-2P/26
XV-2P/30
XV-2P/34
XV-2P/40
41
43
45
47
49
51
53
55
57
59
61
63
04
06
09
11
14
17
19
22
26
30
34
40
6WDQGDUGWKUHDGV
O-O
O-O
O-O
O-O
P-O
P-O
P-O
P-O
Q-P
Q-P
Q-P
Q-P
S-R
S-R
S-R
S-R
S-R
S-R
S-R
S-R
S-R
S-S
S-S
S-S
B-B
B-B
B-B
B-B
C-B
C-B
C-B
C-B
D-C
D-C
D-C
D-C
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
L-M
N
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Z-Z
Internal drainage
O
External drainage
Table showing standard flange and thread

combinations available in stock
Body (threads/flanges)
XP219
30/06/2008
63
Contents
1
1 Disassembly and Assembly of the Pump
1-1
1-1 Tools
1-2
1-2 Procedure of Disassembly
1-3
1-3 Procedure of Assembly
1
Attached Drawing No.1 Exploded Drawing
14
2 K3VL45/A
Attached Drawing No.2 K3VL45/A Cross Section
15
3 K3VL80/A
16
4 K3VL112/A
17
5 K3VL140/A
18
2/
2 Disassembly and Assembly of Pressure Cut-off Load Sensing Regulator
19
2-1
2-1 Tools
19
2-2
20
2-3
22
6
24
7 KR3L-**
Attached Drawing No.7 Cross Section KR3L-* *
25
8 KR3B-**
Attached Drawing No.8 Cross Section KR3B-* *
26
3
3 Disassembly and Assembly of Torque Control Module
27
3-1
3-1 Tools
27
3-2
28
3-3
31
9
34
10 KR3*-**
Attached Drawing No.10 Cross Section KR3*-* *
35
4
4 Judging Standard for Maintenance
36
4-1
4-1 Judging Standard for replacing worn parts
36
4-2
4-2 Judging Standard of cylinder, valve plate, swash plate, and shoe plate
37
1 Disassembly and Assembly of the Pump

1-1Tools
K3VL
The following tables show tools required when disassembling and assembling K3VL pumps.
Tool name and size
Name
Allen wrench
Name
%
B Width
Mark means that the tool

is required.
Size of the pump
45
80
112
140
(mm)
Part name
Hexagon
socket
head bolt
4
5
6
8
10
12
M6
M8
M10
M12
M14
14
17
M16,M18
M20,M22
%
B Width
(mm)
45
80
112
52+
Plug
(ROH type)
G 1/8
G 1/4
G 3/8
G 1/2
G 3/4
Double ring
spanner,
Socket wrench,
Spanner
137)
NPTF 1/16 plug
,62
81)
Plug (UNF thread) Plug (ISO thread)
22

M8
M10
M12,M14
M16,M18
M20
Others
Servo piston
Nut
140
Hexagon
socket
head set
screw
3/4 UNF
24
M14 1.5
M16
M22 1.5
30
32
M20
1-1/16 UNF
M27 2
36
14.3
7/16 UNF
Adjustable
single
wrench

Medium size, 1 piece
Screw driver

Medium size, 2 pieces
,1
Plastic hammer, 1piece
()
Pliers for snap ring(see below)
()
Pliers for retaining ring(see below)
Hammer
Pliers
Torque
wrench
Capable of tightening with specified torque
6$(
,62
0DUNVWDQGVIRUUHTXLUHGIRU6$(PRXQWLQJW\SH
0DUNVWDQGVIRUUHTXLUHGIRU,62PRXQWLQJW\SH
0DUNVWDQGVIRUQRWUHTXLUHG
Plier for snap ring
Plier for retaining ring
1-2
,.
,.
,:
1
2 K3VL45/A
3 K3VL80/A
4 K3VL112/A
5 K3VL140/A
Before disassembling, read all pages of this disassembly section.
When disassembling, follow the order of procedures written in the next table.
Numbers in the parentheses next to the part name shows the part number in
the following drawings:
!Work
!Notes
(1).
(2),.
Select an appropriate place to disassemble.
(1) The place must be clean.

(2) Spread rubber sheet, cloth, etc. to prevent parts from
being damaged.
.
Remove dust, rust, and so on from the surface of the pump
with cleaning oil.
(467),(271).
(1).
Remove the drain plug (467) and drain off hydraulic oil
out of pump casing (271).
(1) Drain off as much oil as possible.
(411,K3VL45,80),(411412,
K3VL112,140),.
(1),.
(2),O-.
(3).
Remove hexagon socket head bolts (411 in case of

K3VL45, 80), (411 and 412 in case of K3VL112, 140),
and then remove the regulator from the casing.
(1) When disassembling the regulator, refer to the manual

of the regulator.
(2) Be careful not to drop O-ring from the gasket surface
of the regulator.
(3) Prevent dust from entering into the regulator.
(312)(401,402).
Loosen hexagon socket head bolt (401, 402) tightening
valve cover(312) and the pump casing.
(1).
(2),
(317)(116).
(3)(271)(312),,
,.
(1) Remove the regulator before loosening the bolts.
(2) In case through drive kit is installed, remove sub-plate
adapter (317) and coupling (116) beforehand.
(3) Oil will come out from between pump casing (271)
and valve cover (312). Be careful and remove oil to
keep the place clean.
!Work
!Notes
(1).(
).
(2),.
(3),,
,,,
.
,(271)(312)
.
Place the pump horizontally on workbench. Separate
pump casing (271) from valve cover (312).
(1) Pull out valve cover perpendicular to the direction of

the shaft. (In order to prevent damage of the needle
bearing and the contacting surface of the shaft.)
(2) Be careful not to damage the contacting surfaces
between valve cover and pump casing.
(3) When removing valve cover, valve plate comes out
attached to valve cover. But valve plate may easily
detach from valve cover and fall down. Be careful not
to damage valve plate.
,(312)(124)
(313)
When necessary, remove needle bearing (124) and valve

plate (313) from valve cover(312).
(1),
.
(2)(808),,.
(1) Do not remove needle bearing unless the bearing is
considered to be near the end of its expected life.
(2) Dot not loosen nut (808). Delivery flow rate will
change when nut is loosened.
(141)(111),,
(151)(153)(156)
(157).
(1),(141)(156)
(152)(151)(212).
(2),.
Pull cylinder (141) out from pump casing straight over

drive shaft. Pull out pistons (151), set plate (153),
spherical bush(156), cylinder springs (157) at the same
time.
(1) Be careful not to damage sliding surfaces of cylinder

(141), spherical bush (156), shoe (152), piston (151),
and swash-plate (212).
(2) Be careful not to damage surface of
the shaft contacting needle bearings.
!Work
!Notes
K3VL45,(406),K3VL80,
112,140,(406).
(261)
(1)K3VL80,112,140,2(
),(261).
(2),(261)(774).
(3),,
.
Remove retaining ring (406) in case of K3VL45 or

hexagon socket head bolts (406) in case of K3VL80,
112, 140. Remove seal cover (261).
(1) In case of K3VL80, 112, 140, seal cover (261) is

easily removed when two bolts are inserted into holes
(with female thread).
(2) Be careful not to damage oil seal (774) on seal cover
(261).
(3) In case of spline shaft, cover spline part with plastic
tape so as not to damage oil seal. In case of key shaft,
remove key before seal cover is removed.
(111),
.
Tapping drive shaft (111) lightly on the end of valve
cover side with a plastic hammer, extract drive shaft
from pump casing.

(1) Hold front side of shaft when tapping to prevent shaft
from flying out.
(2) Tap shaft horizontally (in accordance with shaft direc
tion) not to damage front roller bearing.
(3) As front roller bearing and shaft are fit tightly
(shrinkage fit), do not remove front roller bearing
unless it is considered to be near the end of its expected
life.
10
(532),(211)
(212).

Pushing down servo piston (532), remove shoe plate

(211) and swash plate (212) from pump casing.
(1) Be careful not to damage shoe plate, and the sliding

round surface of swash plate.
11
!Work
!Notes
(271)(251).
Remove swash plate support (251) from pump casing
(271).
(1)(251).
(1) Use both hands to lift up swash plate support (251) .
(532)(548)
/(535,536)(537)
(538).
(1),,
.
(2)
(Three Bond1305B),,.
(3),,
.
12
Only when necessary, remove servo piston (532), tilting

pin (548), outer/inner servo bias springs (535, 536),
spring seat (537), and plug (538).
(1) When removing servo piston, use a special jig not to

damage head part of tilting pin.
(2) Adhesive (Three bond No.1305B) has been applied on
the connecting part between tilting pin and servo iston.
Be careful not to damage servo piston.
(3) Be careful not to clamp fingers by springs when
removing tilting pin from pump casing.
13
1-3!
,,:
(1),,.
(2),,..
.
(3),.
(4)O-,.
(5),O-,,.
(6),,.
When assembling, the order of procedures is the reverse of disassembly. Be careful of next items.
(1) Before assembling, make sure that all parts are prepared and all damaged parts are fixed or replaced by new ones.
(2) Before assembling, wash each part with clean oil and dry it with compressed air. Select an appropriate clean place to
assemble. When dust enters, it may cause trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces and bearings.
(4) Do not reuse O-ring, oil seal, and other seal parts. Replace with new one.
(5) When assembling parts that easily detach, like an O-ring, apply clean grease to prevent them from dropping
downward.
(6) Tighten fitting bolts and plugs using a torque wrench with standard torques shown on the drawing of each size.
!Work
!Notes
.
Select an appropriate place to assemble.
(1).
(2),.
being damaged.
(251)(271).
(1)
,,
.
(2),.
(3),
.(Three Bond1305B)
.
(4)(885),
,.
(5),.
Fit swash plate support in (251) in pump casing (271).
(1) In case servo piston, tilting pin, servo bias springs,

spring seat, and plug were removed, reinstall all parts
before fitting swash plate support.
(2) Be careful not to clamp fingers by springs when
installing springs.
(3) Use a special jig not to damage head part of tilting pin
and feed-back pin. Apply adhesive (Three bond No.
1305B) on thread of servo piston.
(4) Pin (884) has been installed on the inside surface of
pump casing. When installing swash plate support,
make sure that pin enters into the slit of swash plate
support(251).
(5) Be careful not to install swash plate support (251) in
oblique.
(532)(530)
(030),(030)
(211)(271).
Insert tilting pin(530) of the servo piston (532) subassembly into tilting bush of swash plate assembly
(030), then install swash plate assembly (030), and shoe
plate (211) in pump casing (271).
14
(1),,,
.
(2),
.
(1) When inserting, while pushing down servo piston,
insert tilting pin into tilting bush and insert swash plate
into grove of swash plate support correctly.
(2) If grease is applied on rounding surfaces of swash
plate and swash plate support, it is easier to install.
!Work
!Notes
(111)(271),,
.
Insert drive shaft (111) into pump casing (271) tapping
shaft lightly so that height of surface of the pump
casing and height of end of roller bearing are nearly
the same.
(1),.
,.
(2),
.,
.
(1) When tapping shaft, keep shaft in vertical direction.
If tapped strongly, roller bearing may be broken.
(2) Be careful not to push the top surface
of roller bearing deeper than the surface of pump
casing. If the top surface is deeper than the surface of
pump casing, there is a possibility for swash plate
support to be detached.
.
(261).
K3VL80,112,140,
(406),.
K3VL45,,
,(406).
Tape the splined or keyed area of the shaft.
Insert seal cover (261) slightly into pump casing.
In case of K3VL80, 112, 140, tighten hexagon socket
head bolts (406) uniformly to stopping position of the
seal cover and then tighten bolts with a standard torque.
In case of K3VL45, use the hammer to lightly tap the
seal cover to the position where the groove for locking
ring can be seen and then install retaining ring (406).
(1).
(2),.
(3)4.
(4)K3VL45,O-(710),
,,O-(710).
(1) Apply a little grease on lip of oil seal installed in seal
cover.
(2) Be careful not to damage lip of oil seal.
(3) Make sure to tighten the four hexagon socket head
screws evenly.
(4) In case of K3VL45, install Oring(710), apply grease
on outside surface of seal cover, and be careful not to
damage O-ring(710).
!Work
!Notes
(141)(011)(156)
(153)(157).
Assemble cylinder (141), piston-sub (011), spherical
bush (156), set plate (153), and cylinder spring (157)
into a sub assembly.
(1)K3VL45/A,
,
.
(2),,
.
(1) Incase of K3VL45/A Install cylinder spring, ring
guide, and retaining ring into cylinder and then
assemble pin, spacer, spherical bush, set plate, pistonsub to set a subassembly.
(2) Be careful not to damage sliding surfaces between
piston and cylinder bore, and between cylinder and
valve plate.
(271),..
Place pump casing (271) horizontally with surface of
regulator downward. Install piston-cylinder sub into
pump casing.
(1),-,
.
(2),-
.
(1) Be careful not to drop parts for piston-cylinder sub
such as cylinder spring and roller.
(2) Be careful not to damage bearingcontacting surface of
the shaft when installing a piston- cylinder sub.
(312)(313).
(1)(534)(954)
(808),
(312).
(2)(313)/.
,(885)(313)
.
(3)(313)(312)
,(312).
Install valve plate (313) on valve cover (312).
(1) In case that stopper (534), max flow set screw (954),
and max flow set screw lock nut (808) have been
removed, install these parts on valve cover (312)
beforehand.
(2) Do not mistake suction/delivery direction of valve
plate (313). When installing valve plate, make sure that
pin (885) enters into the slit of valve plate (313).
(3) If grease is applied on contacting surfaces of valve
plate (313) and valve cover (312), it is easier to install
valve cover (312).
10
!Work
!Notes
(312) )(271).
(411,K3VL45, 80),(411412,
K3VL112,140)
(1),,
.
Install valve cover (312) on pump casing (271).

Tighten hexagon socket head bolts (411 in case of
K3VL45, 80), (411 and 412 in case of K3VL112, 140),
(1) In assembling valve cover, be careful not to damage

shaft and contacting surface of needle bearing.
(312)(271).
,
Install regulators on the valve cover (312) or pump

casing (271) .
When installing torque limit regulator , make sure that
feed back lever (611) of regulator is engaged with feed
back pin .
(1)O-.
10
11
(1) Make sure that O ring on the gasket surface of regulator

does not drop out.
1
Attached Drawing No.1
Exploded Drawing
Main Pump
Through drive kit
12

( NO K S E AL UB L1 0 1 )
A pp l y l u b ri c an t
( NO K S E AL UB L1 0 1 )
To t he o il sea l
circumierential serface
13
M14
7/16-20UNF
3/4-16UNF
NPTF1/16
M20*1.5
G3/8
M16
465
467
490
531.532
538
808
NOMINAL DESIGNATION
OF SCREW THREAD
401
NO.
TIGHTENING TORQUE

(T hre e Bo n d1 305N )
App l y a dh es i ve
( Th re eb ond N o. 13 05N )
130
74
240
98
12
160

TIGHTENING TORQUE
N*m
PART No
530
030
013
011
PART NAME
TILTING PIN ASS'Y

SWASH PLATE ASS'Y
CYLINDER ASS'Y
PISTON ASSY

C
983
PIN

C
981
NAME PLATE

C
901
EYE BOLT

C
885
SPRING PIN

C
884
PIN

C
824
SNAP RING

C
809
SET SCREW

C
808
NUT

C
803
RETAINING TING

C
792
BACK-UP RING

C
774
OIL SEAL
2
C
729
O-RING
2
C
728
O-RING
2
C
719
O-RING
2
C
711
O-RING
2
C
710
O-RING
2
C
706
O-RING
2
C
703
O-RING
2
C
702
O-RING

/
548
FEED BACK PIN

C
538
PLUG

C
537
SPRING SEAT

C
534
STOPPER

C
533
SPRING

C
532
SERVO PISTON

/
531
TILTING PIN

C
490
PLUG

C
467
PLUG

C
465
PLUG

C
406
RETAINING RING
HEX.S.H.C.SCREW
C
401

/
313
VALVE PLATE

C
312
VALVE COVER

C
271
PUMP CASING

C
261
SEAL COVER

C
251
SWASH PLATE SUPPORT
TILTING BUSH
/
214

/
212
SWASH PLATE

C
211
SHOE PLATE

C
160
SPACER

C
159
ROLLER

C
158
GUIDE RING

C
157
CYLINDER SPRING
SPHERICAL BUSH
C
156

C
153
SET LOATE

/
152
SHOE

/
151
PISTON

/
141
CYLINDER BLOCK

C
127
BEARING SPACER

C
124
NEEDLE BEARING

C
123
ROLLER BEARING

C
111
DRIVE SHAFT

CLASS. PATR No.
PART NAME
CLASS.
B
B
B
B
Q'TY
11ST
1IST
11ST
11ST
SUPPLY CLASSIFHCATION
PATRS SUPPLIED SUB-ASSEMBLED
B
/
%CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
PARTS INDIVIDUALLY SUPPLIED
C
COPPER ALLOY
AL ALLOY
CARBON STEEL
TOOL STEEL
BEARING STEEL
TOOL STEEL
ALLOY STEEL
CARBON STEEL
TOOL STEEL
SYNTHETIC RESIN
FLUORO-RUBBER
NBR
NBR
NBR
NBR
NBR
NBR
FLUORO-RUBBER
FLUORO-RUBBER
BEARING STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
SPRING STEEL
ALLOY STEEL
ALLOY STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
TOOL STEEL
ALLOY STEEL
COPPER ALLOY
DUCTILE
CAST IRON
CARBON STEEL
CAST IRON
BEARING STEEL
DUCTILE
BEARING STEEL
ALLOY STEEL
BEARING STEEL
ALLOY STEEL
SPRING STEEL
CAST IRON
ALLOY STEEL
COPPER ALLOY
ALLOY STEEL
DUCTILE
CARBON STEEL
BEARING STEEL
BEARING STEEL
ALLOY STEEL

MATERIAL

()
CONSTITUENT PART No.(Q'TY)
631(1),648(1)631(IPC).648(1PC)
212(1),214(1)212(1PC).214(1PC)
141(1),313(1)141(1PC).313(1PC)
161(9),162(9)161(9PC).162(9PC)
2
1
1
2
1
2
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
6
2
1
1
4
1
1
1
1
1
1
1
1
1
6
2
1
1
1
9
9
1
2
1
1
1
Q'TY
2 K3VL45/A

(NOK SEALUB L101)
Ap p l y lu b ri ca nt
( NO K S EA LU B L1 0 1)
To t he oi l s ea l
14
M16
M6
7/16-20UNF
3/4-16UNF
NPTF1/16
M22*1.5
G1/2
M16
406
465
467
490
531.532
538
808
NOMINAL DESIGNATION
OF SCREW THREAD
401
NO.
TIGHTENING TORQUE
( Th re e Bo n d1 3 05N )
( Th r eeb o nd N O . 130 5 N)
130
110
240
98
12
12
240

TIGHTENING TORQUE
N*m
PART No
530
030
013
011
PART NAME
TILTING PIN ASS'Y

SWASH PLATE ASS'Y
CYLINDER ASS'Y
PISTON ASSY

C
983
PIN

C
981
NAME PLATE

C
954
SET SCREW

C
901
EYE BOLT

C
886
SPRING PIN

C
885
VALVE PLATE PIN

C
884
PIN

C
824
SNAP RING

C
808
NUT

C
792
BACK-UP RING

C
774
OIL SEAL
2
C
729
O-RING
2
C
728
O-RING
2
C
719
O-RING
2
C
711
O-RING
2
C
710
O-RING
2
C
706
O-RING
2
C
703
O-RING
2
C
702
O-RING

/
548
FEED BACK PIN

C
538
PLUG

C
537
SPRING SEAT

C
536
INNER SPRING

C
535
OUTER SPRING

C
534
STOPPER

C
532
SERVO PISTON

/
531
TILTING PIN

C
490
PLUG

C
467
PLUG

C
465
PLUG
HEX.S.H.C.SCREW
C
406
HEX.S.H.C.SCREW
C
401

/
313
VALVE PLATE

C
312
VALVE COVER

C
271
PUMP CASING

C
261
SEAL COVER

C
251
SWASH PLATE SUPPORT

/
214
TILTING BUSH

/
212
SWASH PLATE

C
211
SHOE PLATE

C
157
CYLINDER SPRING

C
156
SPHERICAL BUSH

C
153
SET PLATE

/
152
SHOE

/
151
PISTON

/
141
CYLINDER BLOCK

C
127
BEARING SPACER

C
124
NEEDLE BEARING

C
123
ROLLER BEARING

C
111
DRIVE SHAFT

CLASS. PATR No.
PART NAME
CLASS.
B
B
B
B
Q'TY
()
631(1),648(1)631(IPC).648(1PC)
212(1),214(1)212(1PC).214(1PC)
141(1),313(1)141(1PC).313(1PC)
161(9),162(9)161(9PC).162(9PC)
COPPER ALLOY
AL ALLOY
CARBON STEEL
CARBON STEEL
TOOL STEEL
BEARING STEEL
BEARING STEEL
TOOL STEEL
CARBON STEEL
SYNTHETIC RESIN
FLUORO-RUBBER
NBR
NBR
NBR
NBR
NBR
NBR
FLUORO-RUBBER
FLUORO-RUBBER
BEARING STEEL
ALLOY STEEL
CARBON STEEL
SPRING STEEL
SPRING STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
ALLOY STEEL
COPPER ALLOY
DUCTILE
CAST IRON
AL ALLOY
CAST IRON
BEARING STEEL
BUCTILE
BEARING STEEL
SPRING STEEL
CAST IRON
ALLOY STEEL
COPPER ALLOY
ALLOY STEEL
DUCTILE
CARBON STEEL
BEARING STEEL
BEARING STEEL

ALLOY STEEL

MATERIAL
11ST
1IST
11ST
11ST
B
/
C
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
1
6
2
1
4
4
1
1
1
1
1
1
1
1
9
1
1
9
9
1
2
1
1
1
Q'TY
3 K3VL80/A

( NO K S E A LU B L1 0 1)
A p pl y l u br i can t
(N OK S E AL UB L 10 1 )
To the oil seal
ci rc um i er en t i al s er fa ce
15
7/16-20UNF
465
1 /10-12UNF
NPTF1/16
M27*1.5
G3/4
M20
467
490
531.532
538
808
M20
M8
406
NOMINAL DESIGNATION
OF SCREW THREAD
401,402
NO.
TIGHTENING TORQUE
( Th re e B on d1 3 05N )
240
170
240
170
12
30
440

TIGHTENING TORQUE
N*m
530
030
013
011
PART No
TILTING PIN ASS'Y

SWASH PLATE ASS'Y
CYLINDER ASS'Y
PISTON ASSY
PART NAME

C
983
PIN

C
981
NAME PLATE

C
954
SET SCREW

C
901
EYE BOLT

C
886
SPRING PIN

C
885
VALVE PLATE PIN

C
884
PIN

C
824
SNAP RING

C
808
NUT

C
792
BACK-UP RING

C
774
OIL SEAL
2
C
729
O-RING
2
C
728
O-RING
2
C
719
O-RING
2
C
711
O-RING
2
C
710
O-RING
2
C
706
O-RING
2
C
703
O-RING
2
C
702
O-RING

/
548
FEED BACK PIN

C
538
PLUG

C
537
SPRING SEAT

C
536
INNER SPRING

C
535
OUTER SPRING

C
534
STOPPER

C
532
SERVO PISTON

/
531
TILTING PIN

C
490
PLUG

C
467
PLUG

C
465
PLUG
HEX.S.H.C.SCREW
C
406
HEX.S.H.C.SCREW
C
402
HEX.S.H.C.SCREW
C
401

/
313
VALVE PLATE

C
312
VALVE COVER

C
271
PUMP CASING

C
261
SEAL COVER

C
251
SWASH PLATE SUPPORT
TILTING BUSH
/
214

/
212
SWASH PLATE

C
211
SHOE PLATE

C
157
CYLINDER SPRING
SPHERICAL BUSH
C
156

C
153
SET PLATE

/
152
SHOE

/
151
PISTON

/
141
CYLINDER BLOCK

C
127
BEARJNG SPACER

C
124
NEEDLE BEARING

C
123
ROLLER BEARING

C
111
DRIVE SHAFT

CLASS. PATR No.
PART NAME
B
B
B
B
CLASS.
11ST
1IST
11ST
11ST
Q'TY
B
/
C
COPPER ALLOY
AL ALLOY
CARBON STEEL
CARBON STEEL
TOOL STEEL
BEARING STEEL
BEARING STEEL
TOOL STEEL
CARBON STEEL
SYNTHETIC RESIN
FLUORO-RUBBER
NBR
NBR
NBR
NBR
NBR
NBR
FLUORO-RUBBER
FLUORO-RUBBER
BEARING STEEL
ALLOY STEEL
CARBON STEEL
SPRING STEEL
SPRING STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
COPPER ALLOY
DUCTILE
CAST IRON
AL ALLOY
CAST IRON
BEARING STEEL
DUCTILE
BEARING STEEL
SPRING STEEL
CAST IRON
ALLOY STEEL
COPPER ALLOY
ALLOY STEEL
DUCTILE
CARBON STEEL
BEARING STEEL
BEARING STEEL
ALLOY STEEL

MATERIAL
631(1),648(1) 631(IPC).648(1PC)
212(1),214(1) 212(1PC).214(1PC)
141(1),313(1) 141(1PC).313(1PC)
161(9),162(9) 161(9PC).162(9PC)
()
2
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
1
6
2
1
4
1
4
1
1
1
1
1
1
1
1
9
1
1
9
9
1
2
1
1
1
Q'TY
.9/$

(N O K S E AL UB L 1 01 )
Ap pl y l u br i can t
(N O K S E AL UB L 1 01 )
To th e o i l s eal
16
7/16-20UNF
465
1 /10-12UNF
NPTF1/16
M27*1.5
G3/4
M20
467
490
531.532
538
808
M20
M8
406
NOMINAL DESIGNATION
OF SCREW THREAD
401,402
NO.
TIGHTENING TORQUE
( Th re e B on d1 305 N )
240
170
240
170
12
30
440

TIGHTENING TORQUE
N*m
983
981
954
901
886
885
884
824
808
792
774
729
728
719
711
710
706
703
702
548
538
537
536
535
534
532
531
490
467
465
406
402
401
313
312
271
261
251
214
212
211
157
156
153
152
151
141
127
124
123
111
11ST
1IST
11ST
11ST
Q'TY
PIN
NAME PLATE
SET SCREW
EYE BOLT
SPRING PIN
VALVE PLATE PIN
PIN
SNAP RING
NUT
BACK-UP RING
OIL SEAL
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
FEED BACK PIN
PLUG
SPRING SEAT
INNER SPRING
OUTER SPRING
STOPPER
SERVO PISTON
TILTING PIN
PLUG
PLUG
PLUG
HEX.S.H.C.SCREW
HEX.S.H.C.SCREW
HEX.S.H.C.SCREW
VALVE PLATE
VALVE COVER
PUMP CASING
SEAL COVER
SWASH PLATE SUPPORT
TILTING BUSH
SWASH PLATE
SHOE PLATE
CYLINDER SPRING
SPHERICAL BUSH
SET PLATE
SHOE
PISTON
CYLINDER BLOCK
BEARJNG SPACER
NEEDLE BEARING
ROLLER BEARING
DRIVE SHAFT
TILTING PIN ASS'Y

SWASH PLATE ASS'Y
CYLINDER ASS'Y
PISTON ASSY
PART NAME

2
2
2
2
2
2
2
2

530
030
013
011
PART No

CLASS. PATR No.
PART NAME
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
/
C
C
C
C
C
C
/
C
C
C
C
C
C
/
C
C
C
C
/
/
C
C
C
C
/
/
/
C
C
C
C
B
B
B
B
CLASS.
B
/
C
COPPER ALLOY
AL ALLOY
CARBON STEEL
CARBON STEEL
TOOL STEEL
BEARING STEEL
BEARING STEEL
TOOL STEEL
CARBON STEEL
SYNTHETIC RESIN
FLUORO-RUBBER
NBR
NBR
NBR
NBR
NBR
NBR
FLUORO-RUBBER
FLUORO-RUBBER
BEARING STEEL
ALLOY STEEL
CARBON STEEL
SPRING STEEL
SPRING STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
DUCTILE
CAST IRON
AL ALLOY
CAST IRON
BEARING STEEL
DUCTILE
BEARING STEEL
SPRING STEEL
CAST IRON
ALLOY STEEL
COPPER ALLOY
ALLOY STEEL
DUCTILE
CARBON STEEL
BEARING STEEL
BEARING STEEL
ALLOY STEEL

MATERIAL
631(1),648(1) 631(IPC).648(1PC)
212(1),214(1) 212(1PC).214(1PC)
141(1),313(1) 141(1PC).313(1PC)
161(9),162(9) 161(9PC).162(9PC)
()
Q'TY
2
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
3
1
1
1
1
1
1
1
1
1
1
6
2
1
4
1
4
1
1
1
1
1
1
1
1
9
1
1
9
9
1
2
1
1
1
5 K3VL140/A
2/
2 Disassembly and Assembly of Pressure Cut-off / Load Sensing Regulator
2-1
/.
1-1 Tools
The following tables show tools required when disassembling and assembling pressure cut-off load
sensing regulator
Tool name and size

B
B Width
Name
(mm)

is required.
Type of regulator
KR3L**
KR3B**
Part name
Hexagon
socket
head bolt
(ROH)
Plug
(ROH type)
Hexagon
socket
head set
screw
GPM1/32
GPM1/32 plug
4
Allen wrench
Name
,
,
Double ring
spanner,
Socket
wrench,
Spanner
Others
5
6
6
M8
B
B Width
(mm)
KR3L**
KR3B**
G 1/8
G 1/4
M8
M10
M12,M14
NPTF1/16
NPTF1/16 plug
Parts
13
Max flow set screw lock nut
19
KR3L:
KR3L: plug for differential spool
27
(M)
(Adapter with M thread)
KR3L:
KR3B:
KR3L:plug for cut-off spool
KR3B:plug for differential spool
30
KR3B:
KR3B:plugfor cut-off spool
32
7/16 UNF(PC,PL)
7/16 UNF plug(for PC, PL port )
14.3
Adjustable
single
wrench
,1
Medium size, 1 piece
Screw driver
,2
Hammer
,1
Plastic hammer, 1piece
Torque wrench
ISO

Mark stands for required for ISO mounting type.
Mark stands
for not required
17
2-2
,.
,.
,:
6
7 KR3L-**
8 KR3B-**
Before disassembling, read all pages of this manual.
Numbers in the parentheses next to the part name shows the part number in the
following drawings:
Attached Drawing No.7 Cross Section KR3L - * *
Attached Drawing No.8 Cross Section KR3B - * *
18
!Work
!Notes
(1).
(2),.
being damaged.
.
1
.
with cleaning oil.
(411),(312).
Remove hexagon socket head bolts (411), and then
remove the regulator from the valve cover (312).
(1),O-.
(2).
(1) Be careful not to drop O-ring (701) from the gasket
surface of the regulator.
(2) Prevent dust from entering into the pump.
(645),(628,629)(624).
(646),(630, 631)(625).
Remove plug (645), and then remove spring (628, 629),
and spring seat (624). Remove plug (646), and then
remove spring (630, 631), and spring seat (625).
(1),.
(2),(647, 648).
(3),(802)(643,644)
(626,627)
(1) Be careful not to damage gasket surface of the regulator.
(2) Be careful not to drop spool (647,648) after removing
plug.
(3) Do not remove nut (802), set screw (643, 644), stopper
(626, 627), unless required.
ROH(423),(647,648).
Loosen ROH plug (423), and remove spool (647,648).
(1),
(1) Be careful not to damage spool.
(490,491)(492,493,494).
Only when necessary, remove plug (490,491), and
orifice (492,493,494).
(1),.
(1) Be careful not to lose plug and orifice.
19
2-3

2
2

When assembling, the order of procedures is the reverse of disassembly.
Be careful of next items.
(1) Before assembling, make sure that all parts are prepared and all damaged parts are
fixed or replaced by new ones.
(2) Before assembling, wash each part with clean oil and dry it with compressed air.
Select an appropriate clean place to assemble. When dust enters, it may cause
trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces and.
(5) When assembling parts that easily detach, like an O-ring, apply clean grease to
prevent them from dropping downward.
(6) Tighten fitting bolts and plugs using a torque wrench with standard torques shown
on the drawing of each size.
20
!Work
!Notes
.
(1).
(2),.
being damaged.
ROH(423),(647,648).
Install ROH plug (423) and then insert spool (647,648).
(1)(490,491)(492,493, 494)
,.
(2),,.
(3)KR3L-**,,
,.
(1) In case the plug (490,491) and orifice (492,493,494) have
been removed, install these parts into regulator casing
beforehand.
(2) When inserting spool, be careful not to damage sliding
surface of the spool.
(3) In case of KR3L-**, be careful not to confuse cut-off
spool and differential spool. Shapes of these spools are
different.
(628,629)(624)(645).
(645).
(630,631)(625)(646).
(646).
Insert spring (628,629) and spring seat (624) into plug
(645).
Install plug (645) on casing.
Insert spring (630,631) and spring seat (625) into plug
(646).
Install plug (646) on casing.
(1)(801)(643,644)
(626,627),.
(2),.
(3),
(645),.
(1) In case when nut (801), set screw (643,644), stopper

(626,627) have been removed, install these parts
beforehand.
(2) Be careful not to install spring and spring seat inclined
or incorrectly.
(3) Install plug for differential spool (645) before
installing plug for cutoff spool to make installing easier.
4(411),
.
Install regulator on pump casing by tightening 4
hexagon socket head bolts (411).
(1)O-(701).
(2)4.
(1) Make sure O-ring (701) is installed correctly.
(2) Tighten 4 bolts evenly.
21
Pressure Cut-off and

Load Sensing Control Detail
6
Exploded Drawing
22
23
,.
Put the casing upright to avoid inclination of the
spring seat and the spring.
B- B
,.
Movement of the the spool and the spring must be
smooth between the contacting suriace.
.,
10mm.
To keep the spring seat and spring in stable positions.
fasten the set screw until its outer and is 10mm from the nut suriace.

Typ e d es igna tion
A - A
, .
647(SP2)648(SP1).
Apply assemble oil before inserting the spool into the casing.
Confirm that the spool moves smoothly.
Be sure not to mistakenly assemble the spool No.647(SP2) in
place of spool No.648(SP1)
,
. 648( SP1)
647( SP2) .
Apply assemble oil before inserting the spool into the
casing. Confirm that the spool moves smoothly.
Be sure not to mistakenly assemble the spool No.648
(SP1) in place of spool No.647(SP2)
C- C
PT1/32
1.5
802
706
705
704
703
702
701
648
647
646
645
644
631
630
629
628
627
626
625
624
601
494
492
491
490
423
422
411
PART NAME
NUT

O-RING
2
O-RING
2
O-RING
2
O-RING
2
O-RING
2
O-RING
2
SPOOL

SPOOL

PLUG

PLUG

SET SCREW

SPRING

SPRING

SPRING

SPRING

STOPPER

STOPPER

SPRING SEAT

SPRING SEAT

CASING

RESTRICTOR

RESTRICTOR

PLUG

PLUG

PLUG

PLUG

HEX.S.H.C.SCREW
&PARTS INDIVIDUALLY SUPPLIED
CLASS. PART No.
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
TIGHTENING
TORQUE
N*m
G1/8
17
M6
12
M8
16
7/16-20UNF
12
G3/8
74
G3/4
170
NPTF1/16
9
NOMINAL
DESIGNATION OF
SCREW THREAD
SUPPLY CLASSIFICATION
423
411
802
422
645
646
490
491
492
494
NO.
TIGHTENING TORQUE
HYDRAULJC CJRCUJT
MATERIAL
ROLL STEEL
NBR
NBR
NBR
NBR
NBR
NBR
ALLOY STEEL
ALLOY STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
SPRING STEEL
SPRING STEEL
SPRING STEEL
SPRING STEEL
ALLOY STEEL
CARBON STEEL
ALLOY STEEL
ALLOY STEEL
CASA IRON
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
7 KR3L-* *
Attached Drawing No.7 Cross Section KR3L - * *
Q'YT
2
1
1
3
1
1
5
1
1
1
1
2
1
1
1
1
1
1
1
1
1
*
*
*
9
2
1
4
24
,.
Put the casing upright to avoid inclination of the
spring seat and the spring.
, .
Movement of the the spool and the spring must be
smooth between the contacting suriace.
. ,
10mm.
To keep the spring seat and spring in stable positions.
fasten the set screw until its outer and is 10mm from the
nut suriace.

Ty pe designation
B- B
A -A
, .
, .
C- C
PT1/32
802
706
705
704
703
702
701
647
646
645
644
643
631
630
629
628
627
626
625
624
601
494
492
491
490
423
422
411
NUT
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
SPOOL
PLUG
PLUG
SET SCREW
SET SCREW
SPRING
SPRING
SPRING
SPRING
STOPPER
STOPPER
SPRING SEAT
SPRING SEAT
CASING
RESTRICTOR
RESTRICTOR
PLUG
PLUG
PLUG
PLUG
HEX.S.H.C.SCREW
PART NAME

2
2
2
2
2
2

1.5
TIGHTENING
TORQUE
N*m
G1/8
17
M8
30
M8
16
7/16-20UNF
12
G3/4
170
G1
220
NPTF1/16
9
NOMINAL
DESIGNATION OF
SCREW THREAD
423
411
802
422
645
646
490
491
492
494
NO.
TJGHTENJNG TORQUE
CLASS. PART No.
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
HYDRAULJC CJRCUJT
MATERIAL
ROLL STEEL
NBR
NBR
NBR
NBR
NBR
NBR
ALLOY STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
ALLOY STEEL
SPRING STEEL
SPRING STEEL
SPRING STEEL
SPRING STEEL
ALLOY STEEL
CARBON STEEL
ALLOY STEEL
ALLOY STEEL
CASA IRON
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
8 KR3B-* *
Attached Drawing No.8 Cross Section KR3B - * *
Q'YT
2
1
1
1
1
1
7
2
1
1
1
1
1
1
1
1
1
1
1
1
1
*
*
*
9
2
1
4
3
3 Disassembly and Assembly of Torque Control Regulator
3-1
.
3-1 Tools
The following tables show tools required when disassembling and assembling torque control regulator
Tool name and size
Name
Allen wrench
Name
,
,
Double ring
spanner,
Socket
wrench,
Spanner
B
B Width
(mm)

is required.
Part name
Type of regulator
4
KR38-**
H
Hexagon
socket
head bolt
(ROH)
Plug
(ROH type)
Hexagon
socket
head set
screw
4
M8
5
M6
G 1/8
M10
M10
G 3/8
M16,M18
B
B Width
(mm)
Others
NPTF 1/6 plug
0R0M18
Part
KR38-**
13
Inner adjustment lock-nut
27
Adjustment plug
41
Outer adjustment lock-nut
Adjustable
single
wrench
,1
Medium size, 1piece
Screw driver
,2
Hammer
,1
Plastic hammer
Pliers
,(3)
Pliers for retaining ring(see page 3)
Steel bar
,108200mm
Steel bar made of material for key, Size approx. 108200mm

Torque wrench
Bolt
M40.75()
M40.75 (used for pulling out pivot plug)
25
3-2
,.
,.
,:
9
10 KR3*-**
Before disassembling, read all pages of this manual.
Numbers in the parentheses next to the part name shows the part number in
the following drawings:
Attached Drawing No.10 Cross Section KR3* - * *
26
!Work
!Notes
(1).
(2),.
being damaged.
.
1
.
with cleaning oil.
(412),.
(1),O-(701,705).
(2).
Remove hexagon socket head bolts (412), and then

remove the regulator from the casing.
(1) Be careful not to drop O-rings (701,705) from the gasket

surface of the regulator.
(2) Prevent dust from entering into the regulator.
(630).
(628)(625,626)(624).
(1),.
(2),,(621).
(3),(801)(924)
(627)
(1) Be careful not to damage gasket surface of the regulator.
(2) Be careful not to drop spool (621), when and after
removing adjusting plug.
(3) Do not remove nut (801), set screw (924), adjustment
stem (627), unless required.
Loosen lock nut (630).

Remove adjusting plug (628), spring (625,626), spring
seat (624).
27
!Work
!Notes
(1)()M41.
(2)(670)(622).
(611),(614),
(611).
(680).
,(614)(611).
Remove locking ring (680).
Using bolt, remove pivot plug(614) and feed back
lever(611).
(1) Size of thread (for pulling out pivot plug) is M41.

(2) Feedback lever is connected to sleeve (622) with pin (670).
While lifting up pivot plug (614) with screw, lift feedback
lever (611) to the direction shown by the arrow in order to
remove feedback lever (611)
(614)
Pivot plug(614)
ROM(650),(621)(622).
(1),.
Remove ROM plug (650) and then push out spool

(621), sleeve(622).
(1) Be careful not to damage spool and sleeve.
28
3-3

2
2

When assembling, the order of procedures is the reverse of disassembly. Be careful of next items.
(1) Before assembling, make sure that all parts are prepared and all damaged parts are fixed or replaced
by new ones.
(2) Before assembling, wash each part with clean oil and dry it with compressed air. Select an appropriate
clean place to assemble. When dust enters,it may cause trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces.
(5) When assembling parts that easily detach, like an O-ring, apply clean grease to prevent them from
dropping downward.
(6) Tighten fitting bolts and plugs using a torque wrench with standard torques shown on the drawing of
each size.
29
!Work
!Notes
.
(1).
(2),.
being damaged.
,,
,(622)
(621).
Adjust the position of the hole for feed back pin on sleeve
to be seen from outside the hole for pivot plug on
regulator casing, insert sleeve (622) and spool (621).
(1)(660),
.
(2),,.
,(611).
(1)(611),
.
(1) In case that plug (660) have been removed, install plug
into regulator casing beforehand.
(2) Be careful not to damage sliding surfaces when assembling
sleeve and spool.
Install feedback lever so that pin (670) of feedback

lever (611) enters into a hole of sleeve.
(1) Adjust the position of the feedback lever (611) so that the
pivot pin hole on the feed back lever can be seen from the
pivot plug hole on casing.
30
!Work
!Notes
(614),(670)
(611).
(680).
(1),.
,.
(2),.
Install pivot plug (614) so that pin (670)of pivot plug

enters into hole of feedback lever (611).
Fix pivot plug by retaining ring (680).
(1) Insert bolt for pulling out on pivot plug.

Apply grease on the surface of pivot plug to make
inserting easy.
(2)Tapping bolt lightly, insert pivot plug into casing.
(625,626)(624)(628).
.
Install spring (625, 626) and spring seat (624) into
adjusting plug (628).
Install these parts on regulator casing.
(1)(801)(924)(624)
,.
(2),.
,
(548).
(412),.
(1)O-(701).
(2)4.
Put regulator on pump casing so that feed back lever

engages with feed back pin in the pump (548).
Fix regulator by tightening hexagon socket head bolts
(412).
(1) Make sure O-ring is installed correctly.

(2) Tighten 4 bolts evenly.
(1) In case that nut (801), set screw (924), and adjustment
stem (627) have been removed, install these parts into
adjusting plug beforehand.
(2) Be careful not to install spring and spring inclined or
incorrectly.
31
Exploded Drawing
Torque Limit Module Detail
9
32
A A
To be assembled
With the groove outside
33
412
630
650
660
801
NO.
M6
M33x1.5
M18x1.5
NPTF1/16
M8
NOMINAL
DESIGNATION OF
SCREW THREAD
N*m
12
102
74
9
16
TIGHTENING
TORQUE
,
.
Each feed back levet
length is different
as shown below.
TJGHTENJNG TORQUE
B B
mm
5
41
8
4
13
WIDTH
ACROSS FLAT
924
801
706
705
704
703
702
701
680
671
670
660
650
630
628
627
626
625
624
622
621
614
611
601
412
CLASS. PART No.
C
C
C
C
C
C
C
C
C
/
/
C
C
C
/
/
/
/
/
/
/
/
/
/
C
B
PART NAME

ADJUST SEREW

NUT
2
O-RING
2
O-RING
2
O-RING
2
O-RING
2
O-RING
2
O-RING

RETAINING RING

PIN

PIN

PLUG

PLUG

LOCK NUT

ADJUST PLUG

ADJUST STEM

INNER SPRING

OUTER SPRING

SPRING SEAT

SLEEVE

SPOOL

PLVOT PLUG

FEED BACK LE VER
CASING
HES.S.H.C.SCREW
REGULATOR ASS'Y

&PARTS SUPPLIED SUB-ASSEMBLED
MATERIAL
CARBON STEEL
ROLL STEEL
NBR
NBR
NBR
NBR
NBR
NBR
TOOL STEEL
CARBON STEEL
BEARING STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
CARBON STEEL
ALLOY STEEL
SPRING STEEL
SPRING STEEL
ALLOY STEEL
ALLOY STEEL
ALLOY STEEL
CARBON STEEL
ALLOY STEEL
CAST IRON
ALLOY STEEL
Q'YT
1
1
1
2
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
4
11ST
10 KR3*-* *
Attached Drawing No.10 Cross Section KR3* - * *
4
Judging Standard for Maintenance
4-1
,.,.
(-,-)
4-1 Judging Standard for replacing worn parts
When each part is worn exceedingly over the following standard, replace or adjust the part. If there is a remarkable
damage, replace or adjust the part.
( Upper standard of initial value, Lower standard of limit for replacing)

standard of initial value / standard of limit for replacing
Measuring item
45
80
112
140
(D-d)
Clearance between cylinder bore
and piston (D-d)
0.019
0.028
0.039
0.039
0.040
0.056
0.067
0.067
()
Endplay between piston and shoe ()
0.1
0.1
0.1
0.1
0.3
3.4
0.3
3.9
0.3
4.9
0.3
4.9
3.2
3.7
4.7
4.7
(L)
Free height of cylinder spring (L)
51.2
50.2
31.3
30.2
41.1
40.3
39.5
38.8
+K
Combined height of set plate
and spherical bush (H-h)
5.0
19.0
23.0
23.0
4.3
18.3
22.0
22.0
(t)
Depth of shoe (t)
Measure
Replacement of piston or cylinder
Replacement of piston-shoe assembly
Replacement of piston-shoe assembly
Replacement of cylinder spring
Replacement of set plate
(:mm)
d
D
(L)
(D-d)
Clearance between cylinder bore and piston. (D-d)
() (t)
Endplay between piston and shoe ( ) Shoe thickness (t)
34
(L)
Free height of cylinder springs (L)
(H-h)
Combined height of set plate and spherical bush (H-h)
4-2.
4-2 Judging Standard of cylinder, valve plate, swash plate, and shoe plate
()
()
()
Roughness of
Valve plate (sliding surface),
Swash plate (surface
contacting with shoe plate),
Cylinder (sliding surface)
standard of limit for

repair
3-Z
standard of initial value

or after repaired
0.4Z
0.4Z or less
35
Kawasaki
STAFFA
STAFFA RADIAL PISTON
HYDRAULIC MOTORS
70
70 SERIES OVERHAUL & MAINTENANCE MANUAL.
!!! CONTENTS.
!PAGE No.
!PAGE CONTENT.
Introduction.
Model Notation
Screw thread torque requirements
Restrictor Screw Identification
Trouble Shooting
10
B7*
Disassembly of B type 7* series motor.
16
B7*
Assembly of B type 7* series motor.
27
C7*
Disassembly of C type 7* series motor
34
C7*
Assembly of C type 7* series motor
44
Required tooling
47
B
Exploded diagram & component identification list for Btype motor.
49
C
Exploded diagram & component identification list for Ctype motor.
STAFFA
!!!!
STAFFA
MOTOR
Overhaul & Maintenance manual
!Introduction.
Staffa
Staffa
When maintaining Staffa radial piston hydraulic motors, the recommendations and specifications detailed throughout this
manual must be followed at all times.
Servicing of Staffa motors should only be carried out by an authorised repairer.
The cleanliness of the workspace and components is of prime importance.
Take note of the following points:
2/
1. 7*BC
2.
3.
1. Preparation.
1. This manual can be used for the disassembly and assembly of 7* series B and C series motors. Before commencing
disassembly, make a note of the model code on the motor ( See section 2 Model code) and become familiar with its
specifications.
2. Prepare the tools required for the specified motor before commencing disassembly. A service tool table is provided ( See
section: Required tooling).
3. The assembly torques specified must be strictly adhered to. Use a correctly calibrated torque wrench.
2/
1.
2.
3.
2. Disassembly.
1. Ensure that your surrounding work area is clean and free from sources of contamination.
2. Spread rubber sheets, cloth, etc., on the work bench to prevent parts from being damaged.
3. If a part seems difficult to remove, stop and examine the component and identify the problem. If impact force is required,
only use a plastic faced mallet.
3/
1.STAFFA
2.
3.
4.O-
3. Assembly.
1. Before re-assembling, check that all parts are in good condition. Damaged parts should either be repaired or replaced. The
life of the motor will be significantly reduced by the use of components which are other than original STAFFA parts.
2. Ensure that all reused components are cleaned and dried before assembly.
3. Apply clean oil to all sliding surfaces i.e. bearings, throws, drums etc.
4. All O rings should be replaced with new.
STAFFA
!!!!
STAFFA
MOTOR
!Model Code.
STAFFAB
The following figure shows the model code for a STAFFA B series motor.
B
Basic B Series Ordering Code
F11 / HM*B / 060 / S3 / FM3 / Tx / * / PL**
[1]
[2]
[3] [4] [5] [6] [7] [8]
[1]
=
F3 = (HFD)
F11 =
[1]
FLUID TYPE
Blank = Mineral Oil
F3 = Phosphate ester (HFD fluid)
F11 = Water based fluids
[2]
= (HMB)
HD = (HMHDB)
[2]
MODEL TYPE
Blank = Standard (HMB)
HD = Heavy Duty (HMHDB)
[3]
[3]
FRAME SIZE
[4]
[4]
SHAFT TYPE
[5]
[5]
MAIN PORT CONNECTIONS
[6]
0
=
T = Staffa
Tx =
[6]
TACHO / ENCODER DRIVE

Blank = None
T = Staffa original tacho drive
Tx = Customer specific encoder drive
[7]
[7]
DESIGN SERIES NUMBER
[8]
PL** = **=
[8]
SPECIAL FEATURES
PL** = Non-catalogued features,
(**) = number assigned as required
Eg: Stainless steel shaft sleeves.
Alternative port connections.
Shaft variants.
Special mountings.
STAFFA
!!!!
STAFFA
MOTOR
)*!!Model Code.(continued)
STAFFAC
The following figure shows the model code for a STAFFA C series motor.
C
Basic C Series Ordering Code
F11 / HM*C / 200 / S3 / 188 / 90 / FM4 / CS / Tx / 30 / PL**
[1]
[2]
[3] [4] [5] [6] [7] [8] [9] [10] [11]
[1]
=
F3 = HFD
F11 =
[1]
FLUID TYPE
Blank = Mineral Oil
F3 = Phosphate ester (HFD fluid)
F11 = Water based fluids
[2]
= (HMC)
HD = (HMHDC)
[2]
MODEL TYPE
Blank = Standard (HMC)
HD = Heavy Duty (HMHDC)
[3]
[3]
FRAME SIZE
[4]
[4]
SHAFT TYPE
[5]
[5]
HIGH DISPLACEMENT CODE
[6]
[6]
LOW DISPLACEMENT CODE
[7]
[7]
MAIN PORT CONNECTIONS
[8]
[8]
DISPLACEMENT CONTROL PORTS

(AND SHUTTLE VALVE)
[9]
0
=
T = Staffa
Tx =
[9]
TACHO / ENCODER DRIVE

T = Staffa original tacho drive
Tx = Customer specific encoder
[10]
[10]
DESIGN SERIES NUMBER
[11]
PL** = **=
[11]
SPECIAL FEATURES
PL** = Non-catalogued features,
(**) = number assigned as required
Eg: Stainless steel shaft sleeves.
Alternative port connections.
Shaft variants.
Special mountings.
STAFFA
!!!!
STAFFA
MOTOR
!Torque Loading
BOLTS
THREAD SIZE
S.H.C.S
HEXAGON HEAD

Imperial Thread
lbft
Imperial lbft
N.m
Metric N.m
lbft
Imperial lbft
N.m
Metric N.m
1/4" UNF / UNC
13 +/- 2
18 +/- 3
9 +/- 2
12 +/- 3
5/16"UNF / UNC
27 +/- 5
37 +/- 7
20 +/- 3
27 +/- 4
3/8"UNF / UNC
45 +/- 5
61 +/- 7
35 +/- 5
48 +/- 7
1/2"UNF / UNC
110 +/- 10
150 +/- 14
85 +/- 5
116 +/- 7
9/16"UNF / UNC
150 +/- 15
204 +/- 21
123 +/- 15
167 +/- 21
5/8"UNF / UNC
215 +/- 20
292 +/- 27
170 +/- 15
231 +/- 21
3/4"UNF / UNC
355 +/- 20
483 +/- 27
290 +/- 20
394 +/- 27
M6
10 +/- 2
14 +/- 3
9 +/- 2
12 +/- 3
M8
27 +/- 5
36 +/- 7
21 +/- 3
29 +/- 4
M10
50 +/- 5
68 +/- 7
40 +/- 5
54 +/- 7
M12
85 +/- 5
116 +/- 7
70 +/- 5
95 +/- 7
M12M12 Nylon Nut
N/A
N/A
70 +/- 5
95 +/- 7
M12/ M12 Lock/Nylon
N/A
N/A
28 +/- 5
38 +/- 7
M14
140 +/- 15
190 +/- 21
116 +/- 15
158 +/- 21
M16
200 +/- 20
272 +/- 27
180 +/- 15
245 +/- 21
M18
280 +/- 20
381 +/- 27
230 +/- 20
313 +/- 27
M18M18 Nyloc Nut
N/A
N/A
230 +/- 20
313 +/- 27
M20
390 +/- 20
530 +/- 27
300 +/- 20
408 +/- 27
M20M20 Nyloc Nut
N/A
N/A
300 +/- 20
408 +/- 27
M24
510 +/- 20
694 +/- 27
430 +/- 20
585 +/- 27
Metric Thread
Values are based on following materials:

Socket head cap screws 170,000lb/in (120kg/mm) UTS - Grades 12.9
Hexagon head screws
114,000lb/in (80kg/mm) UTS - Grades 8.8
STAFFA
!!!!
STAFFA
MOTOR
DOWTYDOWTY BONDED WASHERS

Thread Size
lbft Imperial lbft
N.mMetric N.m
1/8" BSP
M10
5 +/- 0.3
6.8 +/- 0.4
1/4" BSP
M12
12 +/- 0.4 1
6 +/- 0.5
3/8" BSP
M16
23 +/- 1.0
31 +/- 1.4
1/2" BSP
M20
42 +/- 2.0
57 +/- 2.7
3/4" BSP
58 +/- 3.0
79 +/- 4.0
1" BSP
92 +/- 4.0
125 +/- 5.4
3/4" UNF
30 +/- 1.0
41 +/- 1.4
STAFFA
!!!!
STAFFA
MOTOR
!Restrictor Screw Identification
Restrictor Screw Identification Table
Restrictor Face Identification Marks
Size
Thread Size
11 x Circle
.015"
7/16" UNF
22 x Circle
.021"
7/16" UNF
1h2 x Circle and X
.028"
7/16" UNF
Plain Face & X
.040"
7/16" UNF
Plain Face & Groove at Nose End
.019"
7/16" UNF
Plain Face
.5mm
8mm x 1.25p
8 Plain Face and 8
.8mm
7/16" UNF
11 Nm (8 lbs/ft)
loctite542
Restrictor Torque Requirements

Maximum restrictor torque 11 Nm ( 8lbs/ft )
All restrictors must be sealed around their thread using thread locking fluid.
(Suitable fluid, would be loctite 542.)
Care must be taken to ensure the restrictor hole remains clear
STAFFA
!!!!
STAFFA
MOTOR
Trouble Shooting
a
b
c
d
If any problems occur during the running of your motor, before starting any fault diagnosis,
(a) Oil level.
(b) Pressure, flows and temperatures.
(c) Noise and vibration in the system.
(d) Air and oil filters.
check the following:
If a component is found damaged or not to the correct specification, the component and surrounding area should
be cleaned and the component replaced. Whilst cleaning be wary of
flaking paint as this is often a common
cause of system contamination.
Care should be taken when handling components to ensure they do not get damaged.
Fault Diagnosis
Hydraulic Motor
Fault
Motor will not run
STAFFA
!!!!
STAFFA
MOTOR
Possible Causes
Remedy

1.Overload

Release load.

2. Relief valve in the circuit is not
set correctly
Set valve to the correct value

3. Seizure of moving parts
Inspect motor internally and replace

4. Oldhams coupling broken
Inspect valve spool and replace

the required parts.

5.Con - rod restrictor blocked
Replace all restrictors

6. Excessive crankcase leakage
Inspect motor internals and replace

necessary parts with new.

Hydraulic Motor
Fault
Motor Shaft rotates

in reverse direction.
Fall in motor speed
Shaft seal leakage
STAFFA
!!!!
STAFFA
MOTOR
Possible Causes
Remedy
1.
2.
TDC
1. The inlet and outlet pipes have

been connected in reverse.
2. Valve spool has been incorrectly
aligned with the crankshaft.
Change connections.
1.
2.,
3.
4.
5.
6.
7.
1. Drop in flow from pump.

2. Temperature too high causing
excessive pump leakage.
3. Valves worn or broken
4. Piston seal worn or broken
5. Excessive wear between piston and bore.
6. Excessive wear between valve and housing
7. Excessive wear between con - rod and piston.
Check discharge flow from pump.

Reduce oil temperature.

VSHHGLH
1. Shaft seal worn or damaged.

2. High case pressure.
3. Shaft damaged
4. Side loads
5. Incorrect shimming (front or rear).
Replace seal.
Reduce pressure.
Replace or fit speedie sleeve.
Reduce the side load.
Check the bearing & re shim motor.
Align valve spool 'TDC' marks with

crankshaft.
Replace.
Replace.
Replace.
Replace.
Replace.

Hydraulic Motor
Fault
Oil Leakage
Abnormal noise
("CHUFF" noise is
normal.)
STAFFA
!!!!
STAFFA
MOTOR
Possible Causes
Remedy
1.
2.
3.
4.
5.
O-
O-
1.
2.
3.
4.
5.
'O' Ring damaged.

'O' Ring missing
Damage to sealing faces.
Bolts loose.
Broken bolts.
Replace.
Replace and investigate cause.
Disassemble and correct.
Re - tighten to correct torque.
Replace all bolts and re-torque
1.
2.
3.
1. Air in motor ports.

2. Loose front cover.
3.Temperature too high.
Bleed air out.

Correct it or replace.
Reduce temperature
(6) B7*
(6) DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
No.
2/
PROCEDURE
CAUTION
PREPARATION!
Before removing the motor from the installation, clean the

surrounding area. Drain the motorcase by removing the
lower drain plug.
All pipes that are disconnected

should be covered over to prevent
damage and contamination.
All piping that is disconnected should be marked to assist

with reassembly.
REMOVING THE FRONT COVER &

SHAFT SEAL
3/
Support the motor with the drive shaft pointing vertically

upwards. Remove the cap screws bolting the front cover to
the motorcase. Before removing the front cover ensure that
the jacking threads are clean and not damaged.
Ensure that the two screws are

tightened evenly as the front cover
is removed from the motorcase.
Lubricate two of the front cover screws and use them in the
two threaded holes provided to jack the cover up. Remove
the shaft seal using a small flat chisel. The front bearing
cup can be removed using a proprietary cup extractor.

Fig 1.
STAFFA
!!!!
STAFFA
MOTOR
10
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
No.
PROCEDURE
CAUTION
4/
REMOVAL OF SEAL CARRIER (if fitted).
2
If the front cover is fitted with a seal carrier, you should
remove the cap screws first and then using your jacking
screws, remove the seal carrier.
Once the cover and carrier are removed, the shaft seal and
O rings should be removed.
Some seal carriers are not fitted

with jacking screw threads. The
carrier may be removed by using
a small drift on the inside of the
cover.
REMOVING THE CRANKSHAFT ASSEMBLY

& OLDHAMS COUPLING.
5/
First remove the upper con rod retaining ring. Then

carefully lift the con rod slippers clear of the lower ring.
( See fig 3 ).
Ensure that all slippers are clear of

the lower retaining ring.

Fig 3.
Having disconnected the con rods from the lower retaining

ring, push the piston assemblies up into the cylinder bores.
STAFFA
!!!!
STAFFA
MOTOR
11
B7*
No.
PROCEDURE
CAUTION

Next lift the crankshaft out, using a hoist and lifting eye.
Once the crankshaft is clear of the motor, the lower retaining ring, the oldhams coupling can be removed. (See Fig 4).
6/
Take care not to catch the rear

bearing on the con rod slippers or
lower retaining ring.
REMOVING THE FRONT COVER &

SHAFT SEAL

The bearing cones must be removed from the crankshaft by
means of a suitable extractor placed over the bearing
rollers. (See fig 5).
If bearings show any signs of

damage during removal, they must
be renewed.
The crankshaft surface on which
the shaft seal lips run must be kept
clean and free from damage.

Fig5.
The front bearing cup can be removed with a cup extractor.

The rear bearing cup can be removed by pressing or tapping
with an iron drift towards the center of the motor (once the
valve housing has been removed).
STAFFA
!!!!
STAFFA
MOTOR
12
B7*
No.
!7/
PROCEDURE
CAUTION
REMOVAL OF PISTON ASSEMBLY.

Pull the con rod assembly towards the center of the
motor until it clears the piston bore,then remove it from
the motorcase.
Place on a suitable surface and release the circlip with
the circlip pliers.( See fig 6).
Turn the assembly over so that the con rod slipper is
resting on the surface. Rock the piston so that the half
rings will fall clear of the piston. Once this is done the
con rod can be seperated from the piston.
Both the piston seal rings can now be removed.
The restrictor screws should be removed using a
restrictor removal tool. ( See fig 7 ).

Fig 6.
STAFFA
!!!!
STAFFA
MOTOR
loctite 542
loctite 542
When removing the piston assemblies, mark each one to its respective bore.
Care must be taken not to damage
the bronze slipper on the con rod.
If either of the rings are damaged,
they should be replaced.
The restrictors are held with loctite
542 and may be difficult to remove
without the use of the restrictor
tool.

Fig 7.
13
B7*
PROCEDURE
No.
8/
CAUTION
VALVE SPOOL REMOVAL.

90
8
Turn the motor 90 degrees so that the motor is horizontal, do
this by using a hoist and lifting eye. (See fig 8).
8
Remove the cap screws in the end cap, then screw a a lifting
eye into the end of the valve spool. Use the lifting eye to
assist with lifting the spool out of the bore. ( See fig 8).
As a result of close clearances,

jamming may occur when the last
portion of the valve is still in the
bore.
If this does occur, gently tap the

valve back into the bore with a soft
faced hammer and try again.

Fig 8.
Remove the valve seal rings from the valve spool.
9/
VALVE HOUSING REMOVAL.

Remove the cap screws which bolt the valve housing to the
motorcase.
Remove the valve housing using the correct lifting bracket
(See fig 9).
STAFFA
!!!!
STAFFA
MOTOR
14
B7*
PROCEDURE
No.
CAUTION

Fig 9.
Once the valve housing is lifted clear the rear shim , which is
located on the bearing cup, can be removed
Next the rear bearing can be removed by pressing or tapping
with an drift towards the center of the motor.
:/
%
B400 are fitted with an outer

bearing housing which has to be
removed before the bearing cup can
be taken out of the motor.
REMOVAL OF CYLINDER END CAPS.

To remove the cylinder end caps, the end cap screws must
be removed, then the end cap may be withdrawn by using a
drift to tap the end cap from inside the cylinder bore. (See
fig 10).
Care should be taken not to damage

the piston bores.

Fig 10.
STAFFA
!!!!
STAFFA
MOTOR
15
B7*
PROCEDURE
No.
21/
CAUTION
PREPARATION BEFORE REASSEMBLY.
On reassembly of all components, ensure that they are clean

and free of contamination.
Certain components may require a small smear of hydraulic oil
to assist with reassembly.
22/
ASSEMBLE BEARING TO CRANKSHAFT.

Heat the rear bearing to 120deg Celsius then place the bearing
squarely onto the appropriate shaft.
Check that the cone is fully seated by tapping it with a suitable
steel drift. (See fig 11).

the shaft seal contact zone.

Fig 11.
Once the rear bearing has cooled , turn the shaft over and
carry out the same procedure for the front bearing.
STAFFA
!!!!
STAFFA
MOTOR
16
B7*
PROCEDURE
No.
23/
CAUTION
STANDARD FRONT COVER ASSEMBLY.

ORFWLWH

ORFLWH
Apply a small amount of loctite 542 around outer dia

of the cover seal. Then press the seal into the front cover
using the shaft seal insertion tool.(See fig12)
Remove any excess loctite from around the seal or
housing.
The recesses between the lips of the seal should be filled
with a suitable high melting grease.
Take care to ensure that the

shaft seal is fully seated in
the cover.

Fig 12.
24/
FRONT COVER WITH SEAL CARRIER ASSEMBLY.
2

Install the shaft seal. To do this carry out the same
procedures as for a standard front cover.
Once the shaft seal is fitted the carrier can be fitted.
Fit O ring to either seal carrier or to the external
dia of the bearing cup.(See fig13)

Fig 13.
STAFFA
!!!!
STAFFA
MOTOR
17
B7*
PROCEDURE
No.
CAUTION
2
Once the O ring is fitted, the seal carrier can be

assembled to the front cover. Cross tighten the cap
screws to the correct torque setting. (See Sec 4 Torque
Loading).
Press the front bearing cup into the front cover. Ensure
that it is fully seated in the cover by using the insertion
tool.
25/
CON ROD & PISTON SUB ASSEMBLY.

ORFWLWH

Fit the restrictor into the con rod with a smear of loctite 542 on
the thread. Tighten to the required torque setting ( See Sec 5
Restrictor screw identification).
Thinly coat the ball of the con rod with a small amount of
molybdenum grease ( to aid initial running ). Fit the circlip
loosely over the neck of the con rod and partially insert the ball
of the con rod into the piston seat. Insert the two half rings and
push them into the recess until the circlip can be fitted into its
groove. (See fig 14).
When the restrictor is fitted

to the con rod, check that
the hole in the restrictor is
still clear.

Fig 14.
STAFFA
!!!!
STAFFA
MOTOR
18
B7*
PROCEDURE
No.
CAUTION

Cut and fit both seal rings on to the piston groove. ( See fig 15,
which shows how the seal ring should be cut.).
Ensure the nylon back up ring is to

the top of the piston.
90deg.
60deg.

Fig 15.
26/
CON ROD & PISTON SUB ASSEMBLY.

Scarf cut the rings at 45deg to each other (See fig16)
and assemble to valve spool (See fig 17).
On some models steel rings may be

fitted. These have chamfers on both
internal edges and come pre cut.
45
45 deg.
45
45 deg.

Fig 16.
Take care to assemble nylon rings with the chamfered edge face
out.

Fig 17.
STAFFA
!!!!
STAFFA
MOTOR
19
B7*
PROCEDURE
No.
27/
CAUTION
REASSEMBLING PISTON ASSEMBLIES INTO

MOTOR CASING.
&
VALVE HOUSING OR
'C'SPACER MOUNTING
'X'
FACE.
MOTORCASE
Before turning the motor, the bearing cup should be fitted into
the motorcase using the insertion tool. The cup should be
knocked down into the bearing bore to correspond with the
valve housing spigot.(See Dia A).
Now turn the motor to allow the piston to be fitted. Insert the
piston assemblies into the bores from the inside of the motor
housing. The seal rings should be lightly held in its groove
with a small amount of low melting point grease.
REAR BEARING
CRANKSHAFT
Take care not to damagepiston seal.
Push each assembly outwards so the piston is fully retained in

the motorcase piston bores.
28/
REASSEMBLING CRANKSHAFT INTO MOTOR

CASING.
7'&
Place rear retaining ring into the motor case, and hook the ring
under two of the con rods which are at the crankshafts most
eccentric position (TDC) (See fig 18).
Carefully lower the crankshaft into the motor.
Take care not to damage the crankshaft or the bronze slipper frames on
the con rods.

Fig 18.
STAFFA
!!!!
STAFFA
MOTOR
20
B7*
PROCEDURE
No.
CAUTION
+0 %

On some models ( HM*B100 ) the crankshaft needs to be

tipped slightly to allow the rear bearing to go under the rear
retaining ring (See fig 19).
Take care not to damage the bearing

surfaces of the con rod.

Fig 19.
Once the shaft is in and over the rear retaining ring, the con
rods can be lifted over the rear retaining ring. It will be
necessary to carefully rotate the crankshaft, by doing this you
will be able to check that all the con rod slippers rest against
the throw.
Next the top retaining ring can be fitted over the con rods.
Both con rod retaining rings should be able to move freely
around the con rods.
29/
REASSEMBLING THE FRONT COVER TO THE

MOTORCASE.
2
PP
Fit O ring to the spigot of the front cover.
Before fitting the front cover, the splines on the shaft must be
covered to prevent them from getting damaged, to do this use
either a steel sleeve or, when the spline diameter is the same as
the seal diameter, use 50mm masking tape coated with high
melting point grease.
STAFFA
!!!!
STAFFA
MOTOR
21
B7*
PROCEDURE
No.
CAUTION

The front cover should then be placed over the shaft onto the
motorcase and aligned with the screw holes.
Gently tap the cover down squarely until all the front cover
cap screws can be started in their threads. (See fig 20).

Fig 20.
Evenly screw the cover down and tighten the screws to the
recommended torque.
2:/
REFITTING CYLINDER HEADS.

Fig 21.
If the cylinder heads have been removed, a new square section

seal should be fitted (See fig 21).
Tighten the cap screws as below to the required torque.
1
1
4
9
9
Square section seal.
2
3
5
10
HMB060/080/100
STAFFA
!!!!
STAFFA
MOTOR
HMB125/150/200/270/325
22
B7*
PROCEDURE
No.
31/
CAUTION
)C51135*
REPLACING REAR SHIM.
(This procedure does not apply for B400, see page 24)
IWOEV

PP

PP
PPPPPP
Turn motor so the valve housing face is facing up.
Obtain a rolling torque figure with no load acting on the
bearing. Then tap the bearing cup down until the rolling torque
figure increases by 2 to 3 ft lbs.
Zero the depth gauge on the valve housing (See fig 22).
Next measure the depth of the bearing cup in four places to
ensure that the cup is square to the motor case. (See fig 23).
Now add 0.1mm to that depth, this will give you the required
shim pack, which can be fitted to the motor.i.e:
Bearing cup depth = 0.55mm
0.55mm + 0.1mm = 0.65mm shim pack

Fig 22.

Fig 23.
STAFFA
!!!!
STAFFA
MOTOR
23
B7*
PROCEDURE
No.
32/
CAUTION
C511
REPLACING REAR SHIM FOR B400.
$
%
Install inner bearing housing & outer bearing ring (A) in

correct position in the motor case.
Fit clamps (B) in position shown to hold the bearing ring.
Tap the outer bearing ring in evenly until fully located,
indicated by a change in sound when striking the bearing
with the drift.

Fig 24.

Fig 25.
PP(
'
&

PP
Set depth gauge (D) to zero using a 25mm Datum block (E)
( Part No 440-106-177) as illustrated in Fig 25.
Ensure that the bearing is down evenly,

by measuring the height of the bearing
in four places.
Place measurement bridge (C) ( Part No 440-106-176) on the

valve housing mounting face, as shown and measure depth to
bearing face. (See fig 26). Add 0.1mm for (pre load) to determine shim thickness required.

Fig 26.
STAFFA
!!!!
STAFFA
MOTOR
24
B7*
PROCEDURE
No.
22.
CAUTION
ASSEMBLE THE VALVE HOUSING TO THE

MOTORCASE.
22
662
2
Fit the required port O rings and boundary O ring to the
valve housing.
If S03 or S04 valve housing then fit entry port O rings.
Fit O ring retainers into motorcase ports if required.
(See fig 27).

Fig 27.

Now the valve housing can be fitted onto the motorcase using a
suitable lifting bracket. The cap screws should be tightened
evenly to the required torque setting. (See fig 28).
2
Ensure the valve housing is put on in the
correct alignment to the motor case.
Once the valve housing is on the motor
case, do not twist it as it can damage the
O rings.

Fig 28.
7'&7'&
The oldhams coupling can be placed on the end of the shaft, the
valve spool can be carefully lowered into the housing using a
lifting eye. Ensure that the valve spool TDC lines up with the
shaft TDC & engages with the oldhams coupling. The end cap
can now be fitted, tighten cap screws to correct torque.
STAFFA
!!!!
STAFFA
MOTOR
25
B7*
PROCEDURE
No.
23.
CAUTION
REFITTING DRAIN PLUGS.
Fit all gauge plugs and all case drain plugs with new seal
washers.
STAFFA
!!!!
STAFFA
MOTOR
26
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
PROCEDURE
No.
2/
CAUTION
PREPARATION.
Before removing the motor from the installation, clean the

surrounding area. Drain the motorcase by removing the lower
drain plug.

should be covered to prevent
All piping that is disconnected should be marked to

assist with reassembly.
3/
REMOVAL OF CYLINDER END CAPS.
Ensure that the two screws are

tightened evenly as the front cover
is removed from the motorcase.
Support the motor with the drive shaft pointing vertically

upwards. Remove the cap screws bolting the front cover
to the motorcase. Before removing the front cover ensure
that the jacking threads are clean and not damaged.
Lubricate two of the front cover screws and use them in the
two threaded holes provided to jack the cover up. Remove the
shaft seal using a small flat chisel. The front bearing cup can
be removed using a proprietary cup extractor

Fig 29.
STAFFA
!!!!
STAFFA
MOTOR
27
C7*
PROCEDURE
No.
4/
CAUTION
REMOVAL OF SEAL CARRIER (if fitted).
2
If the front cover is fitted with a seal carrier, you should remove
the cap screws first and then using your jacking screws, remove
the seal carrier.

should be covered to prevent
Once the cover and carrier are removed, the shaft seal and O
rings should be removed.
5/
REMOVING THE CRANKSHAFT ASSEMBLY &

OLDHAMS COUPLING.

Remove the upper con rod retaining ring. Then carefully lift
the con rod slippers clear of the lower ring. (See fig 30 ).
Ensure that all slippers are clear of

the lower retaining ring.

Fig 30.
Having disconnected the con rods from the lower retaining

ring, push the piston assemblies up into the cylinder bores.
STAFFA
!!!!
STAFFA
MOTOR
28
C7*
PROCEDURE
No.
CAUTION

Next, using a hoist and lifting eye, lift the crankshaft out.
Once the crankshaft is clear of the motor, the lower retaining ring
and oldhams coupling can be removed. (See Fig 31).
Take care not to catch the rear

bearing on the con rod slippers or
lower retaining ring.

Fig 31.
6/
REMOVAL OF DRUM & BEARINGS.

The bearing cones must be removed from the crankshaft by
means of a suitable extractor placed over the bearing rollers.
(See fig 32).
If bearings show any signs of damage

during removal, they must be enewed.
The crankshaft surface on which the
shaft seal lips run must be kept clean
and free from damage.

Fig 32.
Care should be taken with the small

displacement piston when removing
the drum as it is spring loaded.
&
C rings should be removed from the end of the shaft.

It is advisable to remove the rear bearing first followed by the
spacer plate and drum. Once the drum is clear of the shaft the
displacement pistons can then be removed.
STAFFA
!!!!
STAFFA
MOTOR
29
C7*
PROCEDURE
No.
CAUTION
The front bearing can now be removed without the drum

dropping off.
7/
REMOVAL OF PISTON ASSEMBLY

Pull the con rod assemblys towards the center of the motor
until it clears the piston bore, then remove it from motorcase.
Place on a suitable surface and release the circlip with the
appropriate circlip pliers.(See fig 33).
Turn the assembly over so that the con rod slipper is resting on
the surface. Rock the piston so that the half rings will fall clear
of the piston. Once this is done the con rod can be separated
from the piston.
When removing the piston assemblies, mark each one to its respective
bore.
Care must be taken not to damage the
bronze slipper on the con rod.
If either of the rings are damaged,
they should be replaced.
Both the piston seal rings can now be removed.

Fig 33.
STAFFA
!!!!
STAFFA
MOTOR
30
C7*
PROCEDURE
CAUTION

The restrictor screws may be removed using a restrictor
removal tool. (See fig 34).
ORFWLWH

without the use of the restrictor tool.
No.

Fig 35.
8/
VALVE SPOOL REMOVAL.

Turn the motor 90 degrees so that the motor is horizontal, do

this by using a lifting eye and hoist. (See fig 35).
Remove the cap screws in the end cap. On some models it is

possible to screw a lifting eye into the end of the valve spool
to assist with removal. If the spool does not come with a
tapped hole in the end, it can be removed carefully by hand.
(See fig 35).
Due to the close clearances, jamming

may occur when the last portion of
the valve is still in the bore.
If this does occur, gently tap the valve
back into the bore with a soft faced
hammer and try again.
Care should be taken when handling
steel rings, as they can be very sharp.

Fig 32.
Remove the valve seal rings from the valve spool.
STAFFA
!!!!
STAFFA
MOTOR
31
C7*
PROCEDURE
No.
9/
CAUTION
D.
VALVE HOUSING & C-SPACER REMOVAL.

&

&
Turn the motor a further 90 deg (See fig 36 ).
Remove the cap screws which bolt the valve housing & C-spacer
to the motorcase.
Remove the valve housing using the correct lifting
bracket or a magnetic hoist. (See fig 36 ).
Then remove the C-spacer by hand.
&

without the use of the restrictor tool.

Fig 36.
&
Once the C-spacer is lifted clear, the rear shim located on the
bearing cup can be removed.
:/
REMOVAL OF CYLINDER END CAPS

To remove the cylinder end caps, firstly the end cap screws
must be removed, then the end cap may be withdrawn by
using a small bronze drift to tap the end cap from inside the
cylinder bore. (See fig 37).
Care should be taken not

to damage the piston bores.

Fig 37.
STAFFA
!!!!
STAFFA
MOTOR
32
C7*
PROCEDURE
No.
21/
CAUTION
DT
REMOVAL OF SHUTTLE ASSEMBLIES ( CS Models Only ).
G4GN4
F3 or FM3 Models
%63$
$
Remove shuttle stop plug & 1/4BSP gauge plug (from A port
side). Then push out the shuttle roller, also from the A port side.

Fig 38. Shuttle in valve housing.
G5GN5
F4 or FM4 Motors

Shuttle assembly is located in valve end cap. Remove both
shuttle stop plugs and bonded washers and push out shuttle
from end cap. (See fig 39.)

Fig 39. Shuttle in end cap.
STAFFA
!!!!
STAFFA
MOTOR
33
C7*
PROCEDURE
No.
21/
CAUTION
PREPARATION BEFORE REASSEMBLY.
On reassembly of all components, ensure that they are clean and

free of contamination.
Certain components may require a small smear of hydraulic oil
to assist with reassembly.
22/
ASSEMBLE DRUM & BEARINGS TO SHAFT.

Check that all oil galleries are clean.
Bearings need to be heated to 120 degrees Celsius prior to

fitting. It is recommended that the front spacer and bearing is
fitted first.
The small displacement piston should be fitted with its spring
( See fig 40). Both the large & small displacement pistons
should be fitted into the shaft.

Fig 40.
*
The displacement pistons need to be pushed right down into
their bores, so the drum can be fitted. This is done by using a
G clamp to hold them in place. (See fig 41).

Fig 41.
STAFFA
!!!!
STAFFA
MOTOR
34
C7*
PROCEDURE
No.
CAUTION

Once the drum is located on the shaft, the spacer plates (if fitted)
should be located.
Check the cones are fully seated by tapping them with a suitable
steel drift. ( See fig 42.)

the shaft seal.

POSITION CUTS
AT 180deg.TO
EACH OTHER.

45deg.
42
Fig 42.
&
&
%
The backing rings & C rings can now be fitted to the shaft. The
backing rings should be cut at 45 degrees using a sharp knife
and the C rings should be turned so they are 180 degrees to
each other ( See Dia B ).
23/
B.
Dia B.
ASSEMBLE DRUM & BEARINGS TO SHAFT.

ORFWLWH

ORFLWH
Take care to ensure that the shaft seal

is fully seated in the cover.
Apply a small amount of loctite 542 around the outer Dia of

the shaft seal. Then press the seal into the front cover using the
required shaft seal insertion tool. ( See fig 43.).
Remove any excess loctite from around the seal or housing.
The recess between the lips of the seal should be filled with a
suitable high melting grease.
Press the front cover bearing cup into the front cover.
Ensure that it is fully seated in the cover by using the correct
insertion tool.
STAFFA
!!!!
STAFFA
MOTOR
35
C7*
PROCEDURE
No.
CAUTION
43
Fig 43.
24/
FRONT COVER WITH SEAL CARRIER ASSEMBLY.

( If Fitted.)
2

Firstly install the shaft seal. To do this carry out the same
procedures as for a standard front cover.
Once the shaft seal is fitted the carrier can be fitted.
Fit O Ring to either the seal carrier or to the external
diameter of the bearing cup. ( See fig 44).
44
Fig 44.
2
Once the O Ring is fitted, the seal carrier can be assembled

to the front cover. Cross tighten the cap screws to the correct
torque settings. ( See Section 4 screw thread torque requirements.).
Press the front cover bearing cup into the front cover.
ensure that it is fully seated in the cover by using the correct
insertion tool.
STAFFA
!!!!
STAFFA
MOTOR
36
C7*
PROCEDURE
No.
25/
CAUTION
CON ROD & PISTON ASSEMBLY.

ORFWLWH

Fit the restrictor into the con rod with a small amount of loctite
542 on the thread. Tighten to the required torque setting ( See
section 5 Restrictor screw identification ).
When the restrictor is fitted to the con

rod, check that the hole in the
restrictor is still clear.
Thinly coat the ball of the con rod with a small amount of
molybdenum grease ( to aid initial running in). Fit circlip
loosely over the neck of the con rod and partially insert the
ball of the con rod into the piston seat. Insert the two half rings
and push them into the recess until the circlip can be fitted into
its groove. ( See fig 45 ).
45
Fig 45.

Cut and fit both seal rings on the piston groove.

(See fig 46, which shows how the seal rings should be Cut.).
Ensure the nylon back up ring is to

the top of the piston.
90deg.
60deg.
46
Fig 46.
STAFFA
!!!!
STAFFA
MOTOR
37
C7*
PROCEDURE
No.
26/
CAUTION
VALVE SPOOL SUB ASSEMBLY.

The steel rings need to be fitted. These have chamfers on both
internal edges and come pre cut. Some models may plastic
rings. ( See fig 47).
Care should be taken when fitting

steel rings due to sharp edges.
47
Fig 47.
27/
REASSEMBLING PISTON ASSEMBLIES INTO MOTOR

CASING.
&
valve housing or c spacer
mounting face
&
Before turning the motor, the bearing cup should be fitted into
the motorcase using the insertion tool. The cup should be
knocked down into the bearing bore to correspond with the C
spacer spigot depth. (See fig 48)
Now turn the motor to allow the pistons to be fitted. Insert the
piston assemblies into the bores from the inside of the motor
housing. The seal rings should be lightly held in its groove
with a small amount of low melting point grease to prevent
damage on entry.
motorcase
rear bearing
crankshaft
48
Fig 48.
;&
X is equal to the length of the C

spacer spigot.
Take care not to damage the piston
seals.
Push each assembly outwards so the piston is fully

retained in the motorcase piston bore.
STAFFA
!!!!
STAFFA
MOTOR
38
C7*
PROCEDURE
No.
29/
CAUTION
DT
SHUTTLE SUB ASSEMBLIES( CS Models Only.)
G4GN4
F3, FM3 Valve Housing.
49
Fig 49.
Ensure that the shuttle freely slides in

the housing.
2
Slide shuttle roller in to its bore.
Fit plug with O ring. ( See fig 49.)
G4GN5
F4, FM4 Valve End Cap
22
Fit one shuttle end plug complete with bonded washer to the
end cap.
Slide shuttle in to the bore. Then fit the other end plug and
bonded washer.
Ensure that the shuttle freely slides in

the housing.
Fit the three pilot O rings and valve bore O ring to

is groove.
STAFFA
!!!!
STAFFA
MOTOR
39
C7*
PROCEDURE
No.
28/
CAUTION
REASSEMBLING CRANKSHAFT INTO MOTOR CASING.
7'&
Place rear retaining ring into the motorcase, and hook the ring
under two of the con rods which are at the crankshafts most
eccentric position (TDC) (See fig 50).
Take care not to damage the crankshaft or the bronze faces of the slipper
frames.
Carefully lower the crankshaft into the motor.
50
Fig 50.
Once the shaft is in and over the rear retaining ring, the con
rods can be lifted over the rear retaining ring. It will be
necessary to carefully rotate the crankshaft to check that all the
con rod slippers rest against the throw.
Next the top retaining ring can be fitted over the con rods.
Both con rod retaining rings should be able to move freely
around the con rods.
29/
REASSEMBLING THE FRONT COVER TO THE

MOTORCASE.
2
PP
Fit O ring to the spigot of the front cover.
Before fitting the front cover, the splines on the shaft must be
covered to prevent them from getting damaged, to do this you
can use either a steel sleeve or, when the spline diameter is the
same as the seal diameter, use 50mm masking tape coated with
high melting point grease.
STAFFA
!!!!
STAFFA
MOTOR
40
C7*
PROCEDURE
No.
CAUTION

The front cover should then be placed over the shaft onto the
motorcase and aligned with the screw holes. Gently tap the
cover down squarely until all the front cover cap screws can be
started in their threads. (See fig 51).
Note: All front covers are are interference fits.
51
Fig 51.
Evenly screw the cover down and tighten the screws to

the recommended torque.
19.
REFITTING CYLINDER HEADS.

If the cylinder heads have been removed, a new square

section seal should be fitted ( See fig 52).
Tighten the cap screws as below to the required torque.
52
Fig 52.
1
4
9
9
2
3
3
7
5
10
STAFFA
!!!!
STAFFA
MOTOR
Square section seal.
41
C7*
PROCEDURE
No.
31/
CAUTION
REPLACING REAR SHIM.
IWOEV
1P
&

PP

PP
PPPPPP
Turn the motor over so that valve housing mounting face is
facing up. Firstly obtain a rolling torque figure with no load
acting on the bearing.
Then tap the bearing cup down until the rolling torque figure
increases by 2 to 3 ft lbs. ( 2.7 to 4.1 Nm ).
Zero depth gauge on the C spacer spigot (See fig 53).
Next measure the depth of the bearing cup in four places to
ensure that the cup is square to the motorcase. (See fig 54).
Now add 0.1mm to that depth, this will give you the required
shim pack, which can be fitted to the motor i.e.
Bearing cup depth = 0.55mm
0.55mm + 0.1mm = 0.65mm shim pack.
53
Fig 53.
54
Fig 54.
STAFFA
!!!!
STAFFA
MOTOR
42
C7*
PROCEDURE
No.
21.
CAUTION
D.
ASSEMBLE THE VALVE HOUSING & C SPACER
TO MOTORCASE.
22&
662
2&

Fit the required port O rings and boundary O ring to the
valve housing & C spacer.
If S03 or S04 valve housing then fit entry port O rings.
Fit O ring retainers into motorcase & C spacer ports if
required ( See fig 55).
2
Take care not to damage O rings.
&
Ensure that the C spacer & valve

housing are correctly aligned to
the motorcase.
55
Fig 55.
&
&

The C spacer can be placed onto the motorcase by hand. Now
the valve housing can be fitted onto the C spacer using a
suitable lifting bracket. The cap screws should be tightened
evenly to the required torque setting (See fig 56).
&
2
Once the C spacer & valve housing are
on the motor case , do not twist them
as this can cause damage to O rings.
56
Fig 56.
7'&7'&
The oldhams coupling can be placed on the end of the shaft,

the valve spool can be carefully lowered into the housing with
the aid of a ring compressor sleeve. Ensure that the valve
spool TDC lines up with the shafts TDC & engages with the
oldhams coupling. The end cap can now be fitted, make sure
the cap screws are done up to the correct torque setting.
STAFFA
!!!!
STAFFA
MOTOR
Once the motor is built complete, the

free rolling torque should be measured.
43

REQUIRED TOOLING.
NAME
SHAPE
MODEL TYPE
%%
%%
&&
%
B030 to B100 (Pt No 014801)
B125 to B325 (Pt No 014802)
C125 to C325 (Pt No 014802)
B400
SIZE
1/2 UNF
3/4 UNF
3/4 UNF
3/4 UNF

All Sizes. (Pt No 014740)
))0
6))0
6))0
%
STAFFA
!!!!
STAFFA
MOTOR
F2 - FM2 (Pt No 015055)

S03 - F3 - FM3 (Pt No 015056)
S04 - F4 - FM4 (Pt No 015057)
B010/B030/B080/C030/C045
B100 - C080
B125 - 200 / C125 - 200
B270 - 325 / C270 - 325
HDB 125 - 200
B400
014690
014692
014693
014694
014694
014694
Pt No 014690
Pt No 014692
Pt No 014693
Pt No 014694
Pt No 014694
Pt No 014694
%

B400
(Pt No 440-106-176).
44
)*
REQUIRED TOOLING (cont).
NAME
PP
25 mm Datum
Gauge.
SHAPE
MODEL TYPE
SIZE
B400
( 440-106-176).
B400
(Pt No 440-106-176).
Circlip Pliers
Torque wrench

Hexagon Socket
(1/2 Sq. Drive).
Hexagon
wrench Key.
STAFFA
!!!!
STAFFA
MOTOR
All Sizes
L = 210
0.25N / 20 - 300 Nm
All Sizes
All Sizes
All Sizes
1/2,5/32,7/32,
3/8,
L=60
6mm10mm
1/2, 5/32, 7/32,
3/8, A/F.
L = 60
6mm & 10mm AF.
5/32,7/32,3/8,
1/2,
L=160
5/32, 7/32, 3/8,
1/2, AF.
L = 160
45
)*
REQUIRED TOOLING (cont).
NAME
SHAPE
MODEL TYPE
Depth Mirometer
All Sizes
Bearing Extractor
Most models, see manual.
Ring Compressor
F4, FM4
F3, FM3
Dial Clock gauge
All Sizes
STAFFA
!!!!
STAFFA
MOTOR
SIZE
101 mm
76 mm
Dia. 101mm
Dia. 76mm
0.00 - 5.00 mm
46
B200 7*
B200 7* SERIES EXPLODED DIAGRAM
419
103
486
417
486
485
788
201: 4 + X
402
484
201: 4 = T
484
410
205
201: 4 = P1;P2
484
205
303
201: 4 = Q
201: 4 =S3; S4;

S5; Z3; Z5
101: 2 = HMB;HMHDB
474
435
420
6=
476
404
204
S 04
426
203
305
401
6=
482
102
4
FM
F4;
102
479
105
414
483
202
408
206
415
6=
S04
418
474
479
F
6=
M3
3;F
102
418
102
6=
2
FM
F2;
479
418
301
102
418
405
413
104
Nameplate
418
STAFFA
!!!!
STAFFA
MOTOR
422
47
B7*
COMPONENT IDENTIFICATION LIST FOR B 7* SERIES MOTOR .
Jufn!!Ruz/!!Eftdsjqujpo!
!!!!!
101
102
103
104
105
201
202
203
204
205
206
301
303
305
1
1
1
1
5
1
5
5
10
2
5
1
1
1
401
402
404
405
408
410
413
414
415
417
418
419
420
422
426
435
474
476
479
482
483
484
485
486
488
1
1
5*
12*
5
1*
1*
5*
5*
*
5
10
45
#
2*
2
2*
5*
2
1*
5*
1
1
1
1
O-
O-
O-
O-
O-
O-
48
101
102
103
104
105
201
202
203
204
205
206
301
303
305
1
1
1
1
5
1
5
5
10
2
5
1
1
1
401
402
404
405
408
410
413
414
415
417
418
419
420
422
426
435
474
476
479
482
483
484
485
486
788
1
1
5*
12*
5
1*
1*
5*
5*
*
5
10
45
#
2*
2
2*
5*
2
1*
5*
1
1
1
1
Motorcase
Valve housing
Front cover
Valve end cap
Cylinder head
Crankshaft
Piston
Connecting rod
Piston retaining half ring
Con rod retaining ring
Restrictor screw
Valve spool
Oldham coupling
Shim kit
(steel)
Rear bearing
Front bearing
Piston seal ring
Valve seal ring
Circlip
O-ring (front cover)
O-ring (valve end cap)
O-ring (cylinder end cap)
O-ring (internal ports)
Shaft seal
S.H.C.S (Valve assembly to motor)
S.H.C.S. (front cover)
S.H.C.S (cylinder head cap)
S.H.C.S (valve end cap)
Bonded seal, drain
Drain plug
O-ring (external ports)
Back-up ring (cylinder end cap)
Steel plug (valve housing)
O-ring (valve housing surround)
Piston seal backing ring
Key
Washer, long taper shaft
Nut, taper shaft
Split pin, long taper shaft
B200 7*
B200 7* SERIES EXPLODED DIAGRAM
419
103
456
417
402
201: 4 = Q,Q2
201: 4 = S,Z
251
9=X
456
9 = C,CS,C1,C2
410
Views on Arrow "A"
208
201: 4 = P
209
452
471
303
484
205
205
212
453
454
210
211
401
208
101
206
203
408
202
426
404
435
414
105
204
404
476
402
474
102
415
"A"
479
102
482
415
479
418
305
474
475
102
109
418
497
102
413
418
Nameplate
301
405
104
479
422
418
STAFFA
!!!!
STAFFA
MOTOR
49
B7*
COMPONENT IDENTIFICATION LIST FOR B 7* SERIES MOTOR .
Jufn!!Ruz/!!Eftdsjqujpo!
!!!!!
101
102
103
104
105
201
202
203
204
205
206
209
210
212
214
301
303
305
401
402
404
405
408
410
413
414
415
417
418
419
420
422
426
435
452
453
474
476
479
482
483
484
485
486
788
1
1
1
1
5
1
5
5
10
2
5
1
1
1
1
1
1
1
1
5*
12*
5
1*
1*
5*
5*
*
5
10
45
#
2*
2
1
2*
5*
2
1*
5*
1
1
1
1
O-
O-
O-
O-
O-
O-
101
102
103
104
105
201
202
203
204
205
206
209
210
212
214
301
303
305
401
402
404
405
408
410
413
414
415
417
418
419
420
422
426
435
452
453
474
476
479
482
483
484
485
486
788
50
1
1
1
1
5
1
5
5
10
2
5
1
1
1
1
1
1
1
1
5*
12*
5
1*
1*
5*
5*
*
5
10
45
#
2*
2
1
2*
5*
2
1*
5*
1
1
1
1
Motorcase
Valve housing
Front cover
Valve end cap
Cylinder head
Crankshaft
Piston
Connecting rod
Piston retaining half ring
Con rod retaining ring
Restrictor screw
Large displacement piston
Small displacement piston
Spring (displacement piston)
Front Plate
Valve spool
Oldham coupling
Shim kit (steel)
Rear bearing
Front bearing
Piston seal ring
Valve seal ring
Circlip (piston internal)
O-ring (front cover)
O-ring (valve end cap)
O-ring (cylinder end cap)
O-ring (internal ports)
Shaft seal
S.H.C.S (Valve assembly to motor)
S.H.C.S. (front cover)
S.H.C.S (cylinder head cap)
S.H.C.S (valve end cap)
Bonded seal, drain
Drain plug
Small piston seal ring
Large piston seal ring
O-ring (external ports)
Back-up ring (cylinder end cap)
Steel plug (valve housing)
O-ring (valve housing surround)
Piston seal backing ring
Key
Washer, long taper shaft
Nut, taper shaft
Split pin, long taper shaft

600 KN Towing Winch Manual

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600 KN Towing Winch Manual

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600KN HYDRAULIC TOWING WINCH

600KN HYDRAULIC TOWING WINCH

Chongqing Lange Machinery Group Co., Ltd.

600KN HYDRAULIC TOWING WINCH

2. Main Technical Features

4. Operation and Use Regulations

6. Assembly and Disassembly

7. Towing Winch Operation and Use Regulations

10. Drawing and main structure

11. Electric part drawing

12. Marine proportional valve Service Manual

13. Swash-plate type Axial piston pump Service Manual

14. Hydraulic motors Maintenance Manual

600KN HYDRAULIC TOWING WINCH

Drum load (2st Layer)

Holding load (2st Layer)

Mooring speed (2st Layer)

Light load speed: load 150KN

0-18m/min (2st Layer)

Wire rope diameter

Wire rope standard

3.1 Mechanical Part

Drum Shaft Device

600KN HYDRAULIC TOWING WINCH

with pinion gear fixed on hydraulic motor.

it is connected with fixing bolt and foundation.

600KN HYDRAULIC TOWING WINCH

Hydraulic pump is constant-power controlled axial plunger pump. Pressure oil

Oil tank is design and manufactured by shipyard.

In condition of oil heat because of working at high condition temperature or

600KN HYDRAULIC TOWING WINCH

Operation and Use Regulations

4.1 Attention Before Using

4.2 Operating Hydraulic Towing Winch

Main Drum and Vice Drum

(1) Start hydraulic pump motor.

Main and vice drum wrapping

600KN HYDRAULIC TOWING WINCH

Contact surface of exposed gear should be greased periodically.

All non-machined surfaces of mooring winch should keep clean. Exposed

surfaces should be painted often to prevent rusting.

bolts are loose.

5.2 Maintenance of Operating Valve

Exposed surfaces of operating valve should be painted periodically to prevent

5.3 Protection of Hydraulic System

Hydraulic oil is YB-N68 anti-attrition hydraulic oil. Considering oil viscosity

fluctuated great adapting to temperature, exchange oil adapting to seasonal

600KN HYDRAULIC TOWING WINCH

Observe hydraulic system while running mooring winch. Ensure there is no

abnormal heat, noise and leakage. Obviate immediately if something is failed.

Assembly and Disassembly

6.1 Disassembling Procedure of Mooring Winch

Drain hydraulic oil inside oil tank and pipelines.

Disassemble all hydraulic pipelines.

Disassemble rope guide and fair lead.

Disassemble gear covering.

Disassemble brake rigging.

Disassemble clutch device.

Disassemble hydraulic pump unit.

Disassemble operating valve.

Keep on disassemble other parts continuously if necessary.

600KN HYDRAULIC TOWING WINCH

7. Towing winch Operation and Use Regulations

7.2 Ship towing winch device briefly installation process is as follows