600 KN Towing Winch Manual PDF

600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
600KN HYDRAULIC TOWING WINCH
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 3
2. Main Technical Features 3
3. Structure Instruction 4
4. Operation and Use Regulations 5
5. Maintenance 7
6. Assembly and Disassembly 7
7. Towing Winch Operation and Use Regulations 2
8. Electrical Component 2
9. Operation Instructions 1
10. Drawing and main structure 15
11. Electric part drawing 27
12. Marine proportional valve Service Manual 4
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 pressure-
PAGE 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.
4 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
5 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.
6 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. 3
2. 3
3. 4
4. 5
5. 7
6. 7
7. 2
8. 2
9. 1
10. 15
11. 27
12. 4
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
3.1

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 101917 Rev.0
SPARE PART
NO OFF DIM. DRAW.
DRAW.
DESCRIPTION SPECIFICATION NO OFF
P COMPENSATOR
1 3 MODULATING ELEMENT LRJC-XDN
PA PILOT VALVE
1 12 PRESSURE VALVE RPCC-LQN-HT182
PB NOZZLE
1 10 NOZZLE 0.6 411178
1 49 PLUG 1/8" BSPP VSTI-R
PC SHUTTLE VALVE
1 48 PLUG 1/4" BSPP VSTI-R
1 67 SHUTTLE VALVE WVE-R-1/4" BSPP
Z THROTTLE VALVE
1 24 THROTTLE SCREW 404932A
1 29 O-RING 6.07 x 1.78 SHORE 70
1 30 CAP NUT M8 DIN 1587 A4
1 38 NUT M8 DIN 439B A4
C COUNTERBALANCE VALVE
1 5 SPOOL 303120
1 6 COVER 303121
1 8 SCREW 422971
1 13 SPRING 418686
2 15 SPRING SEAT 421205
1 28 CAP NUT 419936
1 37 NUT 422969
1 45 O-RING 59.50 x 3.00 SHORE 70
2 54 DOWTY PPM-16
2 62 BALL, STEEL RB 10
1 70 PISTON 422232B
CA CHECK VALVE
1 9 SPRING 402852
1 25 SPRING SEAT 402920
1 26 PISTON 400961A
1 46 PLUG 1 1/2" BSPP VSTI-R
Date: 03.05.2005. Rev.0 RECOMMENDED SPARE PARTS
A/S HYDRANOR N-3600 KONGSBERG HIGH QUALITY MARINE HYDRAULICS

DOK 9001.063 Page 2 of 3 4-25531
03890327-E
K3VL

Swash-plate type Axial piston pump

Service Manual

!"
2 !""#
X 2 P 51 42 F S R A
Series X
Group 2

Category P

Displacement 51
Flange 42 0'54 (2)1(43(43953 :=74;
Shaft F 718-% !-"#"/
IN S %%-<
Body
OUT R
/-%-<-
Cover A
$*
Technical data table

7<3( 'LVSODFHPHQW 0D[3UHVVXUH &2'(
FPUHY 3EDU 3EDU /HIWURWDWLRQ 5LJKWURWDWLRQ

XV-2P/04 4,20 260 300 X 2 P 41 41 F S R A X 2 P 41 42 F S R A
XV-2P/30 30,00 160 200 X 2 P 59 41 F S S A X 2 P 59 42 F S S 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 $ % & ' ( ) ' ( ) 2
*
'
(
)
NJ PP PP PP ,1 287 ,1287
287
,1
XV-2P/04 2,330 89,7 41,1 79,7 20 40 M6x1 15 35 M6x1
XV-2P/06 2,430 92,7 41,1 82,7 20 40 M6x2 15 35 M6x1
XV-2P/09 2,530 96,7 43,1 86,7 20 40 M6x3 15 35 M6x1
XV-2P/11 2,630 100,7 47,5 90,7 20 40 M6x4 15 35 M6x1
XV-2P/14 2,730 106,7 47,5 96,7 20 40 M6x5 15 35 M6x1
XV-2P/17 2,830 110,7 47,5 100,7 20 40 M6x6 15 35 M6x1
XV-2P/19 2,930 114,7 47,5 104,7 20 40 M6x7 15 35 M6x1
XV-2P/22 3,180 120,7 55,0 110,7 20 40 M6x8 15 35 M6x1
XV-2P/26 3,280 124,7 55,0 114,7 20 40 M6x9 15 35 M6x1
XV-2P/30 3,530 132,7 63,2 122,7 20 40 M6x10 20 40 M6x1
XV-2P/34 3,730 139,7 63,2 129,7 20 40 M6x11 20 40 M6x1
XV-2P/40 3,930 148,7 63,2 138,7 20 40 M6x12 20 40 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).
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
XP217 www.vivoil.com - english 30/06/2008
60

+
Testo5: 80 FLANGE Shaft Testo5: Cover

Left rotation Right rotation Left rotation Right rotation
CI001 - Parallel CI002 - Parallel
T.2 = 44.1 [Nm] T.2 = 67.5 [Nm]

41 42 A B A
CO001 - Tapered CO002 - Tapered
T.2 = 233.2 [Nm] T.2 = 233.2 [Nm]

E F B
SCF03 - Splined
T.2 = 86.1 [Nm]

H C
Displacement Standard bodies

7<3( &2'( 'LVSODFHPHQWFPUHY 6WDQGDUGWKUHDGV N
XV-2P/04 41 04 O-O S-R B-B L-M Z-Z
XV-2P/06 43 06 O-O S-R B-B L-M Z-Z
XV-2P/09 45 09 O-O S-R B-B L-M Z-Z
XV-2P/11 47 11 O-O S-R B-B L-M Z-Z Internal drainage
XV-2P/14 49 14 P-O S-R C-B L-M Z-Z
XV-2P/17 51 17 P-O S-R C-B L-M Z-Z O
XV-2P/19 53 19 P-O S-R C-B L-M Z-Z
XV-2P/22 55 22 P-O S-R C-B L-M Z-Z
XV-2P/26 57 26 Q-P S-R D-C L-M Z-Z
XV-2P/30 59 30 Q-P S-S D-C L-M Z-Z External drainage
XV-2P/34 61 34 Q-P S-S D-C L-M Z-Z
XV-2P/40 63 40 Q-P S-S D-C L-M Z-Z
Table showing standard flange and thread
combinations available in stock
Body (threads/flanges)
61

/"/&"
2,+ !" ("#
X 2 P 51 52 I S R A
Series X
Group 2

Category P

Displacement 51
Flange 52 0-)(5( :=74;
Shaft I ),%) -%->?@A+?-)(5B%@0@1$/3
IN S %%-<
Body
OUT R
/-%-<-
Cover A
$0
Technical data table

7<3( 'LVSODFHPHQW 0D[3UHVVXUH &2'(
FPUHY 3EDU 3EDU /HIWURWDWLRQ 5LJKWURWDWLRQ

XV-2P/04 4,20 260 300 X 2 P 41 51 I S R A X 2 P 41 52 I S R A
XV-2P/30 30,00 160 200 X 2 P 59 51 I S S A X 2 P 59 52 I S S 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 $ % & ' ( ) ' ( ) 2
*
'
(
)
NJ PP PP PP ,1 287 ,1287
287
,1
XV-2P/04 2,280 88,0 39,4 78,0 20 40 M6x1 15 35 M6x1
XV-2P/06 2,380 91,0 39,4 81,0 20 40 M6x2 15 35 M6x1
XV-2P/09 2,480 95,0 41,4 85,0 20 40 M6x3 15 35 M6x1
XV-2P/11 2,580 99,0 45,8 89,0 20 40 M6x4 15 35 M6x1
XV-2P/14 2,780 105,0 45,8 95,0 20 40 M6x5 15 35 M6x1
XV-2P/17 2,880 109,0 45,8 99,0 20 40 M6x6 15 35 M6x1
XV-2P/19 2,980 113,0 45,8 103,0 20 40 M6x7 15 35 M6x1
XV-2P/22 3,130 119,0 53,3 109,0 20 40 M6x8 15 35 M6x1
XV-2P/26 3,230 123,0 53,3 113,0 20 40 M6x9 15 35 M6x1
XV-2P/30 3,480 131,0 61,5 121,0 20 40 M6x10 20 40 M6x1
XV-2P/34 3,680 138,0 61,5 128,0 20 40 M6x11 20 40 M6x1
XV-2P/40 3,880 147,0 61,5 137,0 20 40 M6x12 20 40 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).
62

+'&
Testo5: 82.5 FLANGE "SAE A" Shaft Testo5: Cover

Left rotation Right rotation Left rotation Right rotation
CI001 - Parallel CI002 - Parallel
T.2 = 44.1 [Nm] T.2 = 67.5 [Nm]

51 52 A B A
CO001 - Tapered CO002 - Tapered
T.2 = 233.2 [Nm] T.2 = 233.2 [Nm]

53 54 E F B
SCF04 - Splined
T.2 = 67.1 [Nm]

I C
Displacement Standard bodies

7<3( &2'( 'LVSODFHPHQWFPUHY 6WDQGDUGWKUHDGV N
XV-2P/04 41 04 O-O S-R B-B L-M Z-Z
XV-2P/06 43 06 O-O S-R B-B L-M Z-Z
XV-2P/09 45 09 O-O S-R B-B L-M Z-Z
XV-2P/11 47 11 O-O S-R B-B L-M Z-Z Internal drainage
XV-2P/14 49 14 P-O S-R C-B L-M Z-Z
XV-2P/17 51 17 P-O S-R C-B L-M Z-Z O
XV-2P/19 53 19 P-O S-R C-B L-M Z-Z
XV-2P/22 55 22 P-O S-R C-B L-M Z-Z
XV-2P/26 57 26 Q-P S-R D-C L-M Z-Z
XV-2P/30 59 30 Q-P S-S D-C L-M Z-Z External drainage
XV-2P/34 61 34 Q-P S-S D-C L-M Z-Z
XV-2P/40 63 40 Q-P S-S D-C L-M Z-Z
Table showing standard flange and thread
combinations available in stock
Body (threads/flanges)
63
Contents
1 3
1 Disassembly and Assembly of the Pump
1-1 3
1-1 Tools
1-2 4
1-2 Procedure of Disassembly
1-3 9
1-3 Procedure of Assembly
1 14
Attached Drawing No.1 Exploded Drawing
2 K3VL45/A 15
Attached Drawing No.2 K3VL45/A Cross Section
3 K3VL80/A 16
4 K3VL112/A 17
5 K3VL140/A 18
2/ 19
2 Disassembly and Assembly of Pressure Cut-off Load Sensing Regulator
2-1 19
2-1 Tools
2-2 20
2-3 22
6 24
7 KR3L-** 25
Attached Drawing No.7 Cross Section KR3L-* *
8 KR3B-** 26
Attached Drawing No.8 Cross Section KR3B-* *
3 27
3 Disassembly and Assembly of Torque Control Module
3-1 27
3-1 Tools
3-2 28
3-3 31
9 34
10 KR3*-** 35
Attached Drawing No.10 Cross Section KR3*-* *
4 36
4 Judging Standard for Maintenance
4-1 36
4-1 Judging Standard for replacing worn parts
4-2 37
4-2 Judging Standard of cylinder, valve plate, swash plate, and shoe plate
1 Disassembly and Assembly of the Pump
1-1Tools
K3VL
The following tables show tools required when disassembling and assembling K3VL pumps.

Mark means that the tool
is required.
Tool name and size Part name
Size of the pump

% 52+
45 80 112 140 Hexagon Hexagon
Name B Width Plug socket Others
socket head set
(mm) head bolt (ROH type) screw
137)
4 M8 NPTF 1/16 plug
5 M6 G 1/8 M10
6 M8 G 1/4 M12,M14
8 M10 G 3/8 M16,M18
Allen wrench
10 M12 G 1/2 M20
12 M14 G 3/4

14 M16,M18 Servo piston
17 M20,M22
% 81) ,62

Name B Width 45 80 112 140 Plug (UNF thread) Plug (ISO thread)
Nut
(mm)
22 3/4 UNF

24 M16 M14 1.5

30 M22 1.5
Double ring
spanner, 32 M20 1-1/16 UNF
Socket wrench,
36 M27 2
Spanner
14.3 7/16 UNF

Adjustable
single Medium size, 1 piece
wrench

Screw driver Medium size, 2 pieces
,1
Hammer Plastic hammer, 1piece
()
Pliers for snap ring(see below)
Pliers ()
Pliers for retaining ring(see below)

Torque Capable of tightening with specified torque
wrench
6$(
,62

0DUNVWDQGVIRUUHTXLUHGIRU6$(PRXQWLQJW\SH
0DUNVWDQGVIRUUHTXLUHGIRU,62PRXQWLQJW\SH
0DUNVWDQGVIRUQRWUHTXLUHG
1

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:
2
!Work !Notes
(1).
Select an appropriate place to disassemble. (2),.
1 (1) The place must be clean.
(2) Spread rubber sheet, cloth, etc. to prevent parts from
being damaged.
.
2
Remove dust, rust, and so on from the surface of the pump
with cleaning oil.
(467),(271). (1).
3 Remove the drain plug (467) and drain off hydraulic oil (1) Drain off as much oil as possible.
out of pump casing (271).
(411,K3VL45,80),(411412, (1),.
K3VL112,140),. (2),O-.
(3).
Remove hexagon socket head bolts (411 in case of
K3VL45, 80), (411 and 412 in case of K3VL112, 140), (1) When disassembling the regulator, refer to the manual
and then remove the regulator from the casing. 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). (1).
Loosen hexagon socket head bolt (401, 402) tightening (2),
valve cover(312) and the pump casing. (317)(116).
(3)(271)(312),,
,.
(1) Remove the regulator before loosening the bolts.
5 (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.
3
!Work !Notes
,(271)(312) (1).(
. ).
(2),.
Place the pump horizontally on workbench. Separate
(3),,
pump casing (271) from valve cover (312).
,,,
.
(1) Pull out valve cover perpendicular to the direction of
6 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) (1),
(313) .
When necessary, remove needle bearing (124) and valve (2)(808),,.
plate (313) from valve cover(312). (1) Do not remove needle bearing unless the bearing is
7
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),, (1),(141)(156)
(151)(153)(156) (152)(151)(212).
(157). (2),.
Pull cylinder (141) out from pump casing straight over (1) Be careful not to damage sliding surfaces of cylinder
drive shaft. Pull out pistons (151), set plate (153), (141), spherical bush (156), shoe (152), piston (151),
spherical bush(156), cylinder springs (157) at the same and swash-plate (212).
time. (2) Be careful not to damage surface of
the shaft contacting needle bearings.
4
!Work !Notes
K3VL45,(406),K3VL80, (1)K3VL80,112,140,2(
112,140,(406). ),(261).
(261) (2),(261)(774).
Remove retaining ring (406) in case of K3VL45 or (3),,
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
9 (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
10 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.
(532),(211)
(212).
Pushing down servo piston (532), remove shoe plate (1) Be careful not to damage shoe plate, and the sliding
(211) and swash plate (212) from pump casing. round surface of swash plate.
11
5
!Work !Notes
(271)(251). (1)(251).
Remove swash plate support (251) from pump casing (1) Use both hands to lift up swash plate support (251) .
(271).
12
(532)(548) (1),,
/(535,536)(537) .
(538). (2)
(Three Bond1305B),,.
Only when necessary, remove servo piston (532), tilting
(3),,
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.
13 (3) Be careful not to clamp fingers by springs when
removing tilting pin from pump casing.
6
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.
7
!Work !Notes
. (1).
Select an appropriate place to assemble. (2),.
being damaged.
(251)(271). (1)
,,
Fit swash plate support in (251) in pump casing (271).
.
(2),.
(3),
.(Three Bond1305B)
.
(4)(885),
,.
(5),.
2 (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) (1),,,
(030),(030) .
(211)(271). (2),
.
Insert tilting pin(530) of the servo piston (532) sub-
assembly into tilting bush of swash plate assembly (1) When inserting, while pushing down servo piston,
(030), then install swash plate assembly (030), and shoe insert tilting pin into tilting bush and insert swash plate
plate (211) in pump casing (271). 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.
14
8
!Work !Notes
(111)(271),, (1),.
. ,.
(2),
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 (1) When tapping shaft, keep shaft in vertical direction.
the same. 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.
4
. (1).
(261). (2),.
K3VL80,112,140, (3)4.
(406),. (4)K3VL45,O-(710),
K3VL45,, ,,O-(710).
,(406).
Tape the splined or keyed area of the shaft. (1) Apply a little grease on lip of oil seal installed in seal
Insert seal cover (261) slightly into pump casing. cover.
In case of K3VL80, 112, 140, tighten hexagon socket (2) Be careful not to damage lip of oil seal.
head bolts (406) uniformly to stopping position of the (3) Make sure to tighten the four hexagon socket head
seal cover and then tighten bolts with a standard torque. screws evenly.
5 In case of K3VL45, use the hammer to lightly tap the (4) In case of K3VL45, install Oring(710), apply grease
seal cover to the position where the groove for locking on outside surface of seal cover, and be careful not to
ring can be seen and then install retaining ring (406). damage O-ring(710).
9
!Work !Notes
(141)(011)(156) (1)K3VL45/A,
(153)(157). ,
Assemble cylinder (141), piston-sub (011), spherical .
bush (156), set plate (153), and cylinder spring (157) (2),,
into a sub assembly. .
(1) Incase of K3VL45/A Install cylinder spring, ring
guide, and retaining ring into cylinder and then
assemble pin, spacer, spherical bush, set plate, piston-
6
sub to set a subassembly.
(2) Be careful not to damage sliding surfaces between
piston and cylinder bore, and between cylinder and
valve plate.
(271),.- (1),-,
. .
Place pump casing (271) horizontally with surface of (2),-
regulator downward. Install piston-cylinder sub into .
pump casing. (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.
7
(312)(313). (1)(534)(954)
(808),
Install valve plate (313) on valve cover (312). (312).
(2)(313)/.
,(885)(313)
.
(3)(313)(312)
,(312).
8 (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). (1),,
(411,K3VL45, 80),(411412, .
K3VL112,140)
Install valve cover (312) on pump casing (271). (1) In assembling valve cover, be careful not to damage
Tighten hexagon socket head bolts (411 in case of shaft and contacting surface of needle bearing.
K3VL45, 80), (411 and 412 in case of K3VL112, 140),
(312)(271). (1)O-.
,

Install regulators on the valve cover (312) or pump (1) Make sure that O ring on the gasket surface of regulator
casing (271) . does not drop out.
When installing torque limit regulator , make sure that
feed back lever (611) of regulator is engaged with feed
back pin .
10
11
1

Main Pump

Through drive kit
12
SUPPLY CLASSIFHCATION
B PATRS SUPPLIED SUB-ASSEMBLED
/ %CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
C PARTS INDIVIDUALLY SUPPLIED

(T hre e Bo n d1 305N ) B 530 TILTING PIN ASS'Y 11ST 631(1),648(1)631(IPC).648(1PC)
App l y a dh es i ve B 030 SWASH PLATE ASS'Y 1IST 212(1),214(1)212(1PC).214(1PC)
( Th re eb ond N o. 13 05N ) B 013 CYLINDER ASS'Y 11ST 141(1),313(1)141(1PC).313(1PC)
2 K3VL45/A
B 011 PISTON ASSY 11ST 161(9),162(9)161(9PC).162(9PC)

()
CLASS. PART No PART NAME Q'TY CONSTITUENT PART No.(Q'TY)
C 983 PIN COPPER ALLOY 2

C 981 NAME PLATE AL ALLOY 1
C 901 EYE BOLT CARBON STEEL 1
C 885 SPRING PIN TOOL STEEL 2
C 884 PIN BEARING STEEL 1
C 824 SNAP RING TOOL STEEL 2
C 809 SET SCREW ALLOY STEEL 1

C 808 NUT CARBON STEEL 1

C 803 RETAINING TING TOOL STEEL 1
C 792 BACK-UP RING SYNTHETIC RESIN 1
C 774 OIL SEAL FLUORO-RUBBER 1
C 729 2 O-RING NBR 1
C 703 2 O-RING FLUORO-RUBBER 1
/ 548 FEED BACK PIN BEARING STEEL 1
13
C 538 PLUG CARBON STEEL 1
C 537 SPRING SEAT CARBON STEEL 1
C 534 STOPPER ALLOY STEEL 1
C 533 SPRING SPRING STEEL 1

C 532 SERVO PISTON ALLOY STEEL 1
( NO K S E AL UB L1 0 1 )
/ 531 TILTING PIN ALLOY STEEL 1
A pp l y l u b ri c an t
( NO K S E AL UB L1 0 1 ) C 490 PLUG CARBON STEEL 6
To t he o il sea l C 467 PLUG CARBON STEEL 2
circumierential serface C 465 PLUG CARBON STEEL 1
C 406 RETAINING RING TOOL STEEL 1
C 401 HEX.S.H.C.SCREW ALLOY STEEL 4
/ 313 VALVE PLATE COPPER ALLOY 1
C 312 VALVE COVER DUCTILE 1
C 271 PUMP CASING CAST IRON 1
C 261 SEAL COVER CARBON STEEL 1
C 251 SWASH PLATE SUPPORT CAST IRON 1
/ 214 TILTING BUSH BEARING STEEL 1
/ 212 SWASH PLATE DUCTILE 1
C 211 SHOE PLATE BEARING STEEL 1
C 160 SPACER ALLOY STEEL 1
C 159 ROLLER BEARING STEEL 6
TIGHTENING TORQUE
C 158 GUIDE RING ALLOY STEEL 2
C 157 CYLINDER SPRING SPRING STEEL 1
TIGHTENING TORQUE
NOMINAL DESIGNATION C 156 SPHERICAL BUSH CAST IRON 1
NO.
OF SCREW THREAD N*m C 153 SET LOATE ALLOY STEEL 1
401 M14 160 / 152 SHOE COPPER ALLOY 9
/ 151 PISTON ALLOY STEEL 9
465 7/16-20UNF 12
/ 141 CYLINDER BLOCK DUCTILE 1
467 3/4-16UNF 98
C 127 BEARING SPACER CARBON STEEL 2
490 NPTF1/16 9 C 124 NEEDLE BEARING BEARING STEEL 1
531.532 M20*1.5 240 C 123 ROLLER BEARING BEARING STEEL 1
C 111 DRIVE SHAFT ALLOY STEEL 1
538 G3/8 74

808 M16 130 CLASS. PATR No. PART NAME MATERIAL Q'TY
( Th re e Bo n d1 3 05N ) / %CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
App l y a dh es i ve C PARTS INDIVIDUALLY SUPPLIED
( Th r eeb o nd N O . 130 5 N)
B 530 TILTING PIN ASS'Y 11ST 631(1),648(1)631(IPC).648(1PC)
B 030 SWASH PLATE ASS'Y 1IST 212(1),214(1)212(1PC).214(1PC)
B 013 CYLINDER ASS'Y 11ST 141(1),313(1)141(1PC).313(1PC)
B 011 PISTON ASSY 11ST 161(9),162(9)161(9PC).162(9PC)
3 K3VL80/A
()

C 954 SET SCREW CARBON STEEL 1
C 885 VALVE PLATE PIN BEARING STEEL 1

14
C 538 PLUG ALLOY STEEL 1

(NOK SEALUB L101) C 537 SPRING SEAT CARBON STEEL 1
Ap p l y lu b ri ca nt C 536 INNER SPRING SPRING STEEL 1
( NO K S EA LU B L1 0 1) C 535 OUTER SPRING SPRING STEEL 1
To t he oi l s ea l C 534 STOPPER ALLOY STEEL 1
circumierential serface
C 532 SERVO PISTON ALLOY STEEL 1
/ 531 TILTING PIN ALLOY STEEL 1
C 261 SEAL COVER AL ALLOY 1

TIGHTENING TORQUE / 214 TILTING BUSH BEARING STEEL 1
/ 212 SWASH PLATE BUCTILE 1

NOMINAL DESIGNATION TIGHTENING TORQUE
NO. C 157 CYLINDER SPRING SPRING STEEL 9
OF SCREW THREAD N*m
C 156 SPHERICAL BUSH CAST IRON 1
401 M16 240
C 153 SET PLATE ALLOY STEEL 1
465 7/16-20UNF 12 / 151 PISTON ALLOY STEEL 9
/ 141 CYLINDER BLOCK DUCTILE 1
467 3/4-16UNF 98
C 127 BEARING SPACER CARBON STEEL 2
538 G1/2 110 C 111 DRIVE SHAFT ALLOY STEEL 1


( Th re e B on d1 3 05N )
App l y a dh es i ve / %CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
( Th r eeb o nd N O . 130 5 N)
B 530 TILTING PIN ASS'Y 11ST 631(1),648(1) 631(IPC).648(1PC)

B 030 SWASH PLATE ASS'Y 1IST 212(1),214(1) 212(1PC).214(1PC)
B 013 CYLINDER ASS'Y 11ST 141(1),313(1) 141(1PC).313(1PC)
B 011 PISTON ASSY 11ST 161(9),162(9) 161(9PC).162(9PC)
()
.9/$


15

C 536 INNER SPRING SPRING STEEL 1
( NO K S E A LU B L1 0 1)
A p pl y l u br i can t C 535 OUTER SPRING SPRING STEEL 1
(N OK S E AL UB L 10 1 ) C 534 STOPPER ALLOY STEEL 1
To the oil seal C 532 SERVO PISTON ALLOY STEEL 1
ci rc um i er en t i al s er fa ce / 531 TILTING PIN ALLOY STEEL 1

TIGHTENING TORQUE
NO. NOMINAL DESIGNATION C 157 CYLINDER SPRING SPRING STEEL 9
OF SCREW THREAD N*m
401,402 M20 440 C 153 SET PLATE ALLOY STEEL 1
1 / 141 CYLINDER BLOCK DUCTILE 1
467 1 /10-12UNF 170
C 127 BEARJNG SPACER CARBON STEEL 2
C 111 DRIVE SHAFT ALLOY STEEL 1
538 G3/4 170


( Th re e B on d1 305 N )
App l y a dh es i ve
( Th r eeb o nd N O . 130 5 N) SUPPLY CLASSIFHCATION
/ %CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
B 530 TILTING PIN ASS'Y 11ST 631(1),648(1) 631(IPC).648(1PC)

B 030 SWASH PLATE ASS'Y 1IST 212(1),214(1) 212(1PC).214(1PC)
B 013 CYLINDER ASS'Y 11ST 141(1),313(1) 141(1PC).313(1PC)
B 011 PISTON ASSY 11ST 161(9),162(9) 161(9PC).162(9PC)
()
5 K3VL140/A


16
C 536 INNER SPRING SPRING STEEL 1
C 535 OUTER SPRING SPRING STEEL 1
(N O K S E AL UB L 1 01 ) C 534 STOPPER ALLOY STEEL 1
Ap pl y l u br i can t C 532 SERVO PISTON ALLOY STEEL 1
(N O K S E AL UB L 1 01 ) / 531 TILTING PIN ALLOY STEEL 1
To th e o i l s eal
circumierential serface
/ 313 VALVE PLATE ALLOY STEEL 1


NOMINAL DESIGNATION TIGHTENING TORQUE
NO. C 157 CYLINDER SPRING SPRING STEEL 9
OF SCREW THREAD N*m
401,402 M20 440
C 153 SET PLATE ALLOY STEEL 1
1 / 141 CYLINDER BLOCK DUCTILE 1
467 1 /10-12UNF 170
C 127 BEARJNG SPACER CARBON STEEL 2
538 G3/4 170 C 111 DRIVE SHAFT ALLOY STEEL 1

808 M20 240
CLASS. PATR No. PART NAME MATERIAL Q'TY
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

is required.
Type of regulator

B KR3L- KR3B- (ROH)
Name B Width Hexagon Plug Hexagon Others
(mm) ** ** socket socket
(ROH type) head set
head bolt
screw
2 GPM1/32
GPM1/32 plug

NPTF1/16
4 NPTF1/16 plug
M8
Allen wrench
5 6 G 1/8 M10
6 M8 G 1/4 M12,M14
B
B Width KR3L- KR3B-
Name (mm) Parts
** **

13 Max flow set screw lock nut
, KR3L:
, 19 KR3L: plug for differential spool

(M)
Double ring 27 (Adapter with M thread)
spanner,
KR3L:
Socket 30
KR3B:
wrench,
Spanner KR3L:plug for cut-off spool
KR3B:plug for differential spool
32 KR3B:
KR3B:plugfor cut-off spool
14.3 7/16 UNF(PC,PL)

7/16 UNF plug(for PC, PL port )

Adjustable ,1
single Medium size, 1 piece
wrench
,2
,1
Hammer Plastic hammer, 1piece

Torque wrench Capable of tightening with specified torque
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).
being damaged.
.
2 Remove dust, rust, and so on from the surface of the pump
with cleaning oil.
(411),(312). (1),O-.
Remove hexagon socket head bolts (411), and then (2).
remove the regulator from the valve cover (312). (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). (1),.
(646),(630, 631)(625). (2),(647, 648).
(3),(802)(643,644)
Remove plug (645), and then remove spring (628, 629),
(626,627)
and spring seat (624). Remove plug (646), and then
remove spring (630, 631), and spring seat (625). (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). (1),
5 Loosen ROH plug (423), and remove spool (647,648). (1) Be careful not to damage spool.
(490,491)(492,493,494). (1),.
6 Only when necessary, remove plug (490,491), and (1) Be careful not to lose plug and orifice.
orifice (492,493,494).
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).
being damaged.
ROH(423),(647,648). (1)(490,491)(492,493, 494)
Install ROH plug (423) and then insert spool (647,648). ,.
(2),,.
(3)KR3L-**,,
2 ,.
(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). (1)(801)(643,644)
(645). (626,627),.
(630,631)(625)(646).
(2),.
(646).
(3),
Insert spring (628,629) and spring seat (624) into plug (645),.
(645).
Install plug (645) on casing. (1) In case when nut (801), set screw (643,644), stopper
Insert spring (630,631) and spring seat (625) into plug (626,627) have been removed, install these parts
(646). beforehand.
Install plug (646) on casing. (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), (1)O-(701).
. (2)4.
Install regulator on pump casing by tightening 4 (1) Make sure O-ring (701) is installed correctly.
hexagon socket head bolts (411). (2) Tighten 4 bolts evenly.
21

Pressure Cut-off and
Load Sensing Control Detail
6
Attached Drawing No.6
Exploded Drawing
22

HYDRAULJC CJRCUJT
7 KR3L-* *

TIGHTENING TORQUE

NOMINAL TIGHTENING
, NO. DESIGNATION OF TORQUE
. 648( SP1) SCREW THREAD N*m
647( SP2) .
Apply assemble oil before inserting the spool into the 423 G1/8 17
Typ e d es igna tion casing. Confirm that the spool moves smoothly. 411 M6 12
Be sure not to mistakenly assemble the spool No.648 802 M8 16
(SP1) in place of spool No.647(SP2)
422 7/16-20UNF 12
645 G3/8 74
646 G3/4 170
490 NPTF1/16 9
491
Attached Drawing No.7 Cross Section KR3L - * *
492 PT1/32 1.5

494

SUPPLY CLASSIFICATION
23
&PARTS INDIVIDUALLY SUPPLIED
C 802 NUT ROLL STEEL 2

C- C C 706 2 O-RING NBR 1
A - A C 703 2 O-RING NBR 1
, .
647(SP2)648(SP1).
C 648 SPOOL ALLOY STEEL 1
Apply assemble oil before inserting the spool into the casing.
Confirm that the spool moves smoothly. C 647 SPOOL ALLOY STEEL 1
,. Be sure not to mistakenly assemble the spool No.647(SP2) in C 646 PLUG CARBON STEEL 1
Movement of the the spool and the spring must be place of spool No.648(SP1) C 645 PLUG CARBON STEEL 1
smooth between the contacting suriace.
,. C 628 SPRING SPRING STEEL 1
Put the casing upright to avoid inclination of the
spring seat and the spring. C 627 STOPPER ALLOY STEEL 1
C 626 STOPPER CARBON STEEL 1
C 625 SPRING SEAT ALLOY STEEL 1
., C 624 SPRING SEAT ALLOY STEEL 1
10mm.
C 601 CASING CASA IRON 1
To keep the spring seat and spring in stable positions.
fasten the set screw until its outer and is 10mm from the nut suriace. C 494 RESTRICTOR CARBON STEEL *
C 492 RESTRICTOR CARBON STEEL *
C 491 PLUG CARBON STEEL *

CLASS. PART No. PART NAME MATERIAL Q'YT
B- B
8 KR3B-* *

HYDRAULJC CJRCUJT

TJGHTENJNG TORQUE

NOMINAL TIGHTENING
NO. DESIGNATION OF TORQUE
SCREW THREAD N*m

423 G1/8 17
Ty pe designation
411 M8 30
802 M8 16
422 7/16-20UNF 12
645 G3/4 170
646 G1 220
490 NPTF1/16 9
491
492 PT1/32 1.5
494
Attached Drawing No.8 Cross Section KR3B - * *

24
, .
Apply assemble oil before inserting the spool into the casing. &PARTS INDIVIDUALLY SUPPLIED
Confirm that the spool moves smoothly.
C 802 NUT ROLL STEEL 2

C- C C 705 2 O-RING NBR 1
A -A C 702 2 O-RING NBR 1
C 647 SPOOL ALLOY STEEL 2
, . C 646 PLUG CARBON STEEL 1
Movement of the the spool and the spring must be
smooth between the contacting suriace. C 645 PLUG CARBON STEEL 1
, . C 644 SET SCREW ALLOY STEEL 1
Apply assemble oil before inserting the spool into the casing.
Confirm that the spool moves smoothly.
,. C 630 SPRING SPRING STEEL 1
Put the casing upright to avoid inclination of the C 629 SPRING SPRING STEEL 1
spring seat and the spring. C 628 SPRING SPRING STEEL 1
C 627 STOPPER ALLOY STEEL 1
C 626 STOPPER CARBON STEEL 1
. , C 625 SPRING SEAT ALLOY STEEL 1
10mm.
To keep the spring seat and spring in stable positions. C 624 SPRING SEAT ALLOY STEEL 1
fasten the set screw until its outer and is 10mm from the C 601 CASING CASA IRON 1
nut suriace.
C 491 PLUG CARBON STEEL *

CLASS. PART No. PART NAME MATERIAL Q'YT
B- B
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

is required.

Type of regulator

B 4 (ROH)

KR38-** Hexagon Hexagon
Name B Width Plug socket
(mm) H socket Others
head set
head bolt (ROH type) screw
4
M8 NPTF 1/6 plug
Allen wrench 5 M6 G 1/8 M10
8 M10 G 3/8 M16,M18 0R0M18
B
B Width KR38-**
Name (mm) Part
,
, 13
Inner adjustment lock-nut

Double ring 27
spanner, Adjustment plug
Socket
wrench,
Spanner 41 Outer adjustment lock-nut

Adjustable ,1
single Medium size, 1piece
wrench
,2
,1
Hammer Plastic hammer
,(3)
Pliers Pliers for retaining ring(see page 3)
,108200mm
Steel bar Steel bar made of material for key, Size approx. 108200mm

Torque wrench Capable of tightening with specified torque
M40.75()
Bolt 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).
being damaged.
.
2 Remove dust, rust, and so on from the surface of the pump
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). (1),.
(628)(625,626)(624). (2),,(621).
Loosen lock nut (630). (3),(801)(924)
Remove adjusting plug (628), spring (625,626), spring (627)
seat (624). (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.
27
!Work !Notes
(680). (1)()M41.
,(614)(611). (2)(670)(622).
(611),(614),
Remove locking ring (680). (611).
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 (1) Be careful not to damage spool and sleeve.
(621), sleeve(622).
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).
being damaged.
,, (1)(660),
,(622) .
(621). (2),,.
Adjust the position of the hole for feed back pin on sleeve (1) In case that plug (660) have been removed, install plug
to be seen from outside the hole for pivot plug on into regulator casing beforehand.
regulator casing, insert sleeve (622) and spool (621). (2) Be careful not to damage sliding surfaces when assembling
sleeve and spool.
,(611). (1)(611),
.
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) (1),.
(611). ,.
(680). (2),.
Install pivot plug (614) so that pin (670)of pivot plug (1) Insert bolt for pulling out on pivot plug.
enters into hole of feedback lever (611). Apply grease on the surface of pivot plug to make
Fix pivot plug by retaining ring (680). inserting easy.
(2)Tapping bolt lightly, insert pivot plug into casing.
4
(625,626)(624)(628). (1)(801)(924)(624)
. ,.
Install spring (625, 626) and spring seat (624) into (2),.
adjusting plug (628).
Install these parts on regulator casing. (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
5 incorrectly.
, (1)O-(701).
(548). (2)4.
(412),.
Put regulator on pump casing so that feed back lever (1) Make sure O-ring is installed correctly.
engages with feed back pin in the pump (548). (2) Tighten 4 bolts evenly.
Fix regulator by tightening hexagon socket head bolts
(412).
31
9
Torque Limit Module Detail

32

To be assembled
With the groove outside
10 KR3*-* *
A A
Attached Drawing No.10 Cross Section KR3* - * *
33

&PARTS SUPPLIED SUB-ASSEMBLED
%CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
&PARTS INDIVIDUALLY SUPPLIED
, C 924 ADJUST SEREW CARBON STEEL 1

. C 801 NUT ROLL STEEL 1
B B Each feed back levet C 706 2 O-RING NBR 1
length is different
as shown below.
C 680 RETAINING RING TOOL STEEL 1
/ 671 PIN CARBON STEEL 1
/ 670 PIN BEARING STEEL 2
C 630 LOCK NUT CARBON STEEL 1
/ 628 ADJUST PLUG CARBON STEEL 1
/ 627 ADJUST STEM ALLOY STEEL 1
/ 626 INNER SPRING SPRING STEEL 1

/ 625 OUTER SPRING SPRING STEEL 1
TJGHTENJNG TORQUE
/ 624 SPRING SEAT ALLOY STEEL 1

/ 622 SLEEVE ALLOY STEEL 1
WIDTH
NOMINAL TIGHTENING / 621 SPOOL ALLOY STEEL 1
NO. TORQUE ACROSS FLAT
DESIGNATION OF / 614 PLVOT PLUG CARBON STEEL 1
SCREW THREAD N*m mm
/ 611 FEED BACK LE VER ALLOY STEEL 1
412 M6 12 5
/ 601 CASING CAST IRON 1
630 M33x1.5 102 41
C 412 HES.S.H.C.SCREW ALLOY STEEL 4
650 M18x1.5 74 8
B - REGULATOR ASS'Y - 11ST
660 NPTF1/16 9 4

801 M8 16 13 CLASS. PART No. PART NAME MATERIAL Q'YT
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 Measure
45 80 112 140
(D-d) 0.019 0.028 0.039 0.039

Clearance between cylinder bore
Replacement of piston or cylinder
and piston (D-d) 0.040 0.056 0.067 0.067
() 0.1 0.1 0.1 0.1
Endplay between piston and shoe () Replacement of piston-shoe assembly
0.3 0.3 0.3 0.3
(t) 3.4 3.9 4.9 4.9
Depth of shoe (t) Replacement of piston-shoe assembly
3.2 3.7 4.7 4.7
(L) 51.2 31.3 41.1 39.5
Free height of cylinder spring (L) Replacement of cylinder spring
50.2 30.2 40.3 38.8
5.0 19.0 23.0 23.0
+K
Combined height of set plate Replacement of set plate
and spherical bush (H-h)
4.3 18.3 22.0 22.0
(:mm)
(L)
(D-d)
Clearance between cylinder bore and piston. (D-d) (L)
Free height of cylinder springs (L)
H
a
h
t
() (t) (H-h)
Endplay between piston and shoe ( ) Shoe thickness (t) Combined height of set plate and spherical bush (H-h)
34
4-2.
4-2 Judging Standard of cylinder, valve plate, swash plate, and shoe plate

() 3-Z
standard of limit for
()
repair
()
Roughness of
Valve plate (sliding surface),
Swash plate (surface
0.4Z
contacting with shoe plate), standard of initial value
0.4Z or less
Cylinder (sliding surface) or after repaired
35
Kawasaki
STAFFA
STAFFA RADIAL PISTON
HYDRAULIC MOTORS
70
70 SERIES OVERHAUL & MAINTENANCE MANUAL.
!!! CONTENTS.
!PAGE No. !PAGE CONTENT.
1
Introduction.
2
Model Notation
4
Screw thread torque requirements
6
Restrictor Screw Identification
7
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 Overhaul & Maintenance manual
MOTOR
!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
!!!!
MOTOR
1
!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] [1] FLUID TYPE

= Blank = Mineral Oil
F3 = (HFD) F3 = Phosphate ester (HFD fluid)
F11 = F11 = Water based fluids
[2] [2] MODEL TYPE

= (HMB) Blank = Standard (HMB)
HD = (HMHDB) HD = Heavy Duty (HMHDB)
[3] [3] FRAME SIZE
[4] [4] SHAFT TYPE
[5] [5] MAIN PORT CONNECTIONS
[6] 0 [6] TACHO / ENCODER DRIVE

= Blank = None
T = Staffa T = Staffa original tacho drive
Tx = Tx = Customer specific encoder drive
[7] [7] DESIGN SERIES NUMBER
[8] [8] SPECIAL FEATURES

PL** = **= PL** = Non-catalogued features,
(**) = number assigned as required
Eg: Stainless steel shaft sleeves.
Alternative port connections.
Shaft variants.
Special mountings.
STAFFA
!!!!
MOTOR
2
)*!!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] [1] FLUID TYPE

= Blank = Mineral Oil
F3 = HFD F3 = Phosphate ester (HFD fluid)
F11 = F11 = Water based fluids
[2] [2] MODEL TYPE

= (HMC) Blank = Standard (HMC)
HD = (HMHDC) 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 [9] TACHO / ENCODER DRIVE

= T = Staffa original tacho drive
T = Staffa Tx = Customer specific encoder
Tx =
[10] [10] DESIGN SERIES NUMBER
[11] [11] SPECIAL FEATURES

PL** = **= PL** = Non-catalogued features,
(**) = number assigned as required
Eg: Stainless steel shaft sleeves.
Alternative port connections.
Shaft variants.
Special mountings.
STAFFA
!!!!
MOTOR
3
!Torque Loading
BOLTS
THREAD SIZE S.H.C.S HEXAGON HEAD
lbft N.m lbft N.m
Imperial Thread Imperial lbft Metric N.m Imperial lbft 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
Metric Thread
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
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
!!!!
MOTOR
4
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
!!!!
MOTOR
5
!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
!!!!
MOTOR
6
Trouble Shooting
a
b
c
d
If any problems occur during the running of your motor, before starting any fault diagnosis, check the following:
(a) Oil level.
(b) Pressure, flows and temperatures.
(c) Noise and vibration in the system.
(d) Air and oil filters.
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 Possible Causes Remedy

Motor will not run 1.Overload Release load.

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

3. Seizure of moving parts Inspect motor internally and replace

Inspect valve spool and replace
4. Oldhams coupling broken the required parts.

5.Con - rod restrictor blocked Replace all restrictors

Inspect motor internals and replace
6. Excessive crankcase leakage necessary parts with new.
STAFFA
!!!!
MOTOR
7

Hydraulic Motor
1.
Motor Shaft rotates 2. TDC
in reverse direction. 1. The inlet and outlet pipes have Change connections.
been connected in reverse.
2. Valve spool has been incorrectly Align valve spool 'TDC' marks with
aligned with the crankshaft. crankshaft.
1.
Fall in motor speed 2.,
3.
4.
5.
6.
7.
1. Drop in flow from pump. Check discharge flow from pump.

2. Temperature too high causing Reduce oil temperature.
excessive pump leakage.
3. Valves worn or broken Replace.
4. Piston seal worn or broken Replace.
5. Excessive wear between piston and bore. Replace.
6. Excessive wear between valve and housing Replace.
7. Excessive wear between con - rod and piston. Replace.

Shaft seal leakage VSHHGLH

1. Shaft seal worn or damaged. Replace seal.
2. High case pressure. Reduce pressure.
3. Shaft damaged Replace or fit speedie sleeve.
4. Side loads Reduce the side load.
5. Incorrect shimming (front or rear). Check the bearing & re shim motor.
STAFFA
!!!!
MOTOR
8

Hydraulic Motor
1. O-
Oil Leakage 2. O-
3.
4.
5.
1. 'O' Ring damaged. Replace.
2. 'O' Ring missing Replace and investigate cause.
3. Damage to sealing faces. Disassemble and correct.
4. Bolts loose. Re - tighten to correct torque.
5. Broken bolts. Replace all bolts and re-torque
1.
2.
Abnormal noise 3.
("CHUFF" noise is
normal.) 1. Air in motor ports. Bleed air out.
2. Loose front cover. Correct it or replace.
3.Temperature too high. Reduce temperature
STAFFA
!!!!
MOTOR
9
(6) B7*
(6) DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
No. PROCEDURE CAUTION

2/
PREPARATION!

Before removing the motor from the installation, clean the All pipes that are disconnected
surrounding area. Drain the motorcase by removing the should be covered over to prevent
lower drain plug. damage and contamination.
All piping that is disconnected should be marked to assist
with reassembly.
3/
REMOVING THE FRONT COVER &
SHAFT SEAL

Support the motor with the drive shaft pointing vertically Ensure that the two screws are
upwards. Remove the cap screws bolting the front cover to tightened evenly as the front cover
the motorcase. Before removing the front cover ensure that is removed from the motorcase.
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 1.
STAFFA
!!!!
MOTOR
10
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.

4/
REMOVAL OF SEAL CARRIER (if fitted).

2
If the front cover is fitted with a seal carrier, you should Some seal carriers are not fitted
remove the cap screws first and then using your jacking with jacking screw threads. The
screws, remove the seal carrier. carrier may be removed by using
Once the cover and carrier are removed, the shaft seal and a small drift on the inside of the
O rings should be removed. cover.
5/
REMOVING THE CRANKSHAFT ASSEMBLY
& OLDHAMS COUPLING.

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

Fig 3.

Having disconnected the con rods from the lower retaining
ring, push the piston assemblies up into the cylinder bores.
STAFFA
!!!!
MOTOR
11
B7*

Next lift the crankshaft out, using a hoist and lifting eye.
Take care not to catch the rear
Once the crankshaft is clear of the motor, the lower retain-
bearing on the con rod slippers or
ing ring, the oldhams coupling can be removed. (See Fig 4).
lower retaining ring.
6/
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
!!!!
MOTOR
12
B7*

!7/
REMOVAL OF PISTON ASSEMBLY.

loctite 542

loctite 542

Pull the con rod assembly towards the center of the
When removing the piston assem-
motor until it clears the piston bore,then remove it from
blies, mark each one to its respec-
the motorcase.
tive bore.
Place on a suitable surface and release the circlip with Care must be taken not to damage
the circlip pliers.( See fig 6). the bronze slipper on the con rod.
If either of the rings are damaged,
Turn the assembly over so that the con rod slipper is they should be replaced.
resting on the surface. Rock the piston so that the half The restrictors are held with loctite
rings will fall clear of the piston. Once this is done the 542 and may be difficult to remove
con rod can be seperated from the piston. without the use of the restrictor
Both the piston seal rings can now be removed. tool.
The restrictor screws should be removed using a
restrictor removal tool. ( See fig 7 ).

Fig 6. Fig 7.
STAFFA
!!!!
MOTOR
13
B7*
8/
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). As a result of close clearances,
jamming may occur when the last
portion of the valve is still in the
8 bore.
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).

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
!!!!
MOTOR
14
B7*

Fig 9.
%

Once the valve housing is lifted clear the rear shim , which is B400 are fitted with an outer
located on the bearing cup, can be removed bearing housing which has to be
Next the rear bearing can be removed by pressing or tapping removed before the bearing cup can
with an drift towards the center of the motor. be taken out of the motor.
:/
REMOVAL OF CYLINDER END CAPS.

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

Fig 10.
STAFFA
!!!!
MOTOR
15
B7*
21/
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 Care should be taken not to damage
squarely onto the appropriate shaft. the shaft seal contact zone.
Check that the cone is fully seated by tapping it with a suitable
steel drift. (See fig 11).

Fig 11.
Once the rear bearing has cooled , turn the shaft over and
carry out the same procedure for the front bearing.
STAFFA
!!!!
MOTOR
16
B7*

23/
STANDARD FRONT COVER ASSEMBLY.
ORFWLWH

ORFLWH

Apply a small amount of loctite 542 around outer dia Take care to ensure that the
of the cover seal. Then press the seal into the front cover shaft seal is fully seated in
using the shaft seal insertion tool.(See fig12) the cover.
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.

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
!!!!
MOTOR
17
B7*

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 When the restrictor is fitted
the thread. Tighten to the required torque setting ( See Sec 5 to the con rod, check that
Restrictor screw identification). the hole in the restrictor is
Thinly coat the ball of the con rod with a small amount of still clear.
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).

Fig 14.
STAFFA
!!!!
MOTOR
18
B7*

Cut and fit both seal rings on to the piston groove. ( See fig 15, Ensure the nylon back up ring is to
which shows how the seal ring should be cut.). 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) On some models steel rings may be
and assemble to valve spool (See fig 17). 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
!!!!
MOTOR
19
B7*

27/
REASSEMBLING PISTON ASSEMBLIES INTO
MOTOR CASING.

$
&
VALVE HOUSING OR
'X'
'C'SPACER MOUNTING
FACE.

MOTORCASE
Before turning the motor, the bearing cup should be fitted into
REAR BEARING
the motorcase using the insertion tool. The cup should be

CRANKSHAFT
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 Take care not to damagepiston seal.
with a small amount of low melting point grease.
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 Take care not to damage the crank-
under two of the con rods which are at the crankshafts most shaft or the bronze slipper frames on
eccentric position (TDC) (See fig 18). the con rods.
Carefully lower the crankshaft into the motor.

Fig 18.
STAFFA
!!!!
MOTOR
20
B7*

+0 %

On some models ( HM*B100 ) the crankshaft needs to be Take care not to damage the bearing
tipped slightly to allow the rear bearing to go under the rear surfaces of the con rod.
retaining ring (See fig 19).

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
!!!!
MOTOR
21
B7*

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 4
1
4 8 7 6
6 9
9 8

3 2 Square section seal.
3 2
7 5
10 5
HMB060/080/100 HMB125/150/200/270/325
STAFFA
!!!!
MOTOR
22
B7*

31/
)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
!!!!
MOTOR
23
B7*

32/ 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(
'
& Ensure that the bearing is down evenly,
by measuring the height of the bearing
PP in four places.
Set depth gauge (D) to zero using a 25mm Datum block (E)
( Part No 440-106-177) as illustrated in Fig 25.
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 deter-
mine shim thickness required.

Fig 26.
STAFFA
!!!!
MOTOR
24
B7*

22.
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 2
suitable lifting bracket. The cap screws should be tightened
evenly to the required torque setting. (See fig 28). 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
!!!!
MOTOR
25
B7*

23.
REFITTING DRAIN PLUGS.

Fit all gauge plugs and all case drain plugs with new seal
washers.
STAFFA
!!!!
MOTOR
26
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.

2/
PREPARATION.

Before removing the motor from the installation, clean the All pipes that are disconnected
surrounding area. Drain the motorcase by removing the lower should be covered to prevent
drain plug. damage and contamination.
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
!!!!
MOTOR
27
C7*

4/
REMOVAL OF SEAL CARRIER (if fitted).

2
If the front cover is fitted with a seal carrier, you should remove All pipes that are disconnected
the cap screws first and then using your jacking screws, remove should be covered to prevent
the seal carrier. damage and contamination.
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 Ensure that all slippers are clear of
the con rod slippers clear of the lower ring. (See fig 30 ). 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
!!!!
MOTOR
28
C7*

Next, using a hoist and lifting eye, lift the crankshaft out. Take care not to catch the rear
Once the crankshaft is clear of the motor, the lower retaining ring bearing on the con rod slippers or
and oldhams coupling can be removed. (See Fig 31). 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.
Care should be taken with the small

Fig 32. 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
!!!!
MOTOR
29
C7*

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

Fig 33.
STAFFA
!!!!
MOTOR
30
C7*
ORFWLWH
The restrictor screws may be removed using a restrictor
removal tool. (See fig 34). The restrictors are held with loctite
542 and may be difficult to remove
without the use of the restrictor tool.

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 Due to the close clearances, jamming
to assist with removal. If the spool does not come with a may occur when the last portion of
tapped hole in the end, it can be removed carefully by hand. the valve is still in the bore.
(See fig 35).
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
!!!!
MOTOR
31
C7*

9/ D.
VALVE HOUSING & C-SPACER REMOVAL.
&
&

&
Turn the motor a further 90 deg (See fig 36 ). The restrictors are held with loctite
Remove the cap screws which bolt the valve housing & C-spacer 542 and may be difficult to remove
to the motorcase. without the use of the restrictor tool.
Remove the valve housing using the correct lifting
bracket or a magnetic hoist. (See fig 36 ).
Then remove the C-spacer by hand.

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

Fig 37.
STAFFA
!!!!
MOTOR
32
C7*

21/ 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
!!!!
MOTOR
33
C7*

21/
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
!!!!
MOTOR
34
C7*

Once the drum is located on the shaft, the spacer plates (if fitted) Care should be taken not to damage
should be located. the shaft seal.
Check the cones are fully seated by tapping them with a suitable
steel drift. ( See fig 42.)

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 B.
and the C rings should be turned so they are 180 degrees to Dia B.
each other ( See Dia B ).
23/
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
!!!!
MOTOR
35
C7*
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 require-
ments.).
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
!!!!
MOTOR
36
C7*

25/
CON ROD & PISTON ASSEMBLY.
ORFWLWH

Fit the restrictor into the con rod with a small amount of loctite When the restrictor is fitted to the con
542 on the thread. Tighten to the required torque setting ( See rod, check that the hole in the
section 5 Restrictor screw identification ). 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. Ensure the nylon back up ring is to
(See fig 46, which shows how the seal rings should be Cut.). the top of the piston.
90deg.
60deg.
46
Fig 46.
STAFFA
!!!!
MOTOR
37
C7*

26/
VALVE SPOOL SUB ASSEMBLY.

The steel rings need to be fitted. These have chamfers on both Care should be taken when fitting
internal edges and come pre cut. Some models may plastic steel rings due to sharp edges.
rings. ( See fig 47).
47
Fig 47.
27/
REASSEMBLING PISTON ASSEMBLIES INTO MOTOR
CASING.
&
valve housing or c spacer
mounting face
&

motorcase

rear bearing

crankshaft

48
Before turning the motor, the bearing cup should be fitted into Fig 48.
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 X is equal to the length of the C
piston assemblies into the bores from the inside of the motor spacer spigot.
housing. The seal rings should be lightly held in its groove Take care not to damage the piston
with a small amount of low melting point grease to prevent seals.
damage on entry.
Push each assembly outwards so the piston is fully
retained in the motorcase piston bore.
STAFFA
!!!!
MOTOR
38
C7*

29/ 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 Ensure that the shuttle freely slides in
end cap. the housing.
Slide shuttle in to the bore. Then fit the other end plug and
bonded washer.
Fit the three pilot O rings and valve bore O ring to
is groove.
STAFFA
!!!!
MOTOR
39
C7*

28/
REASSEMBLING CRANKSHAFT INTO MOTOR CASING.

7'&

Place rear retaining ring into the motorcase, and hook the ring Take care not to damage the crank-
under two of the con rods which are at the crankshafts most shaft or the bronze faces of the slipper
eccentric position (TDC) (See fig 50). 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
!!!!
MOTOR
40
C7*

The front cover should then be placed over the shaft onto the Note: All front covers are are interfer-
motorcase and aligned with the screw holes. Gently tap the ence fits.
cover down squarely until all the front cover cap screws can be
started in their threads. (See fig 51).
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 52
section seal should be fitted ( See fig 52). Fig 52.
Tighten the cap screws as below to the required torque.
1 4
1
4 8 7 6
9
9 8
3
3 2
7 5 Square section seal.
10 5
STAFFA
!!!!
MOTOR
41
C7*

31/
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
!!!!
MOTOR
42
C7*

21. D.
ASSEMBLE THE VALVE HOUSING & C SPACER
TO MOTORCASE.
22& 2
662 Take care not to damage O rings.
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).
&

Ensure that the C spacer & valve
housing are correctly aligned to
the motorcase.
55
Fig 55.
&
& &
2
The C spacer can be placed onto the motorcase by hand. Now Once the C spacer & valve housing are
the valve housing can be fitted onto the C spacer using a on the motor case , do not twist them
suitable lifting bracket. The cap screws should be tightened as this can cause damage to O rings.
evenly to the required torque setting (See fig 56).
56
Fig 56.

7'&7'& Once the motor is built complete, the
free rolling torque should be measured.
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
!!!!
MOTOR
43

REQUIRED TOOLING.
NAME SHAPE MODEL TYPE SIZE

%% 1/2 UNF
%% 3/4 UNF
&& 3/4 UNF
% 3/4 UNF
B030 to B100 (Pt No 014801)
B125 to B325 (Pt No 014802)
C125 to C325 (Pt No 014802)
B400

All Sizes. (Pt No 014740)
))0
6))0
6))0
F2 - FM2 (Pt No 015055)
S03 - F3 - FM3 (Pt No 015056)
S04 - F4 - FM4 (Pt No 015057)
014690
014692
B010/B030/B080/C030/C045 014693
014694
B100 - C080
014694
B125 - 200 / C125 - 200 014694
B270 - 325 / C270 - 325 Pt No 014690
HDB 125 - 200 Pt No 014692
Pt No 014693
B400 Pt No 014694
Pt No 014694
Pt No 014694
%

%
B400
(Pt No 440-106-176).
STAFFA
!!!!
MOTOR
44
)*
REQUIRED TOOLING (cont).
B400
PP ( 440-106-176).
25 mm Datum B400
Gauge. (Pt No 440-106-176).

L = 210
Circlip Pliers All Sizes
0.25N / 20 - 300 Nm
Torque wrench All Sizes
1/2,5/32,7/32,
3/8,
L=60

6mm10mm

All Sizes 1/2, 5/32, 7/32,
Hexagon Socket
(1/2 Sq. Drive). 3/8, A/F.
L = 60
6mm & 10mm AF.
5/32,7/32,3/8,
1/2,
L=160
Hexagon All Sizes 5/32, 7/32, 3/8,

wrench Key. 1/2, AF.
L = 160
STAFFA
!!!!
MOTOR
45
)*
REQUIRED TOOLING (cont).

Depth Mirometer All Sizes

Bearing Extractor Most models, see manual.
101 mm
F4, FM4 76 mm
Ring Compressor F3, FM3 Dia. 101mm
Dia. 76mm

Dial Clock gauge All Sizes 0.00 - 5.00 mm
STAFFA
!!!!
MOTOR
46
B200 7*
B200 7* SERIES EXPLODED DIAGRAM
419
103
486
417
486
485
788
201: 4 + X
402
484
201: 4 = T
410 484
205
201: 4 = P1;P2
484
205
303
201: 4 = Q 201: 4 =S3; S4;

S5; Z3; Z5
101: 2 = HMB;HMHDB
474
435 S 04
420 6=
476
404 204
426
203
305 4 102
FM
401 F4;
6=
482 102
479
105 414 483 206
202 408 415 S04 474
418
6=
479
M3 102
F 3;F 418
6=
102
2 479
FM
F2; 418
6=
102 301
418
405 413
104
Nameplate
418
422
STAFFA
!!!!
MOTOR
47
B7*
COMPONENT IDENTIFICATION LIST FOR B 7* SERIES MOTOR .
!!!!! Jufn!!Ruz/!!Eftdsjqujpo!
101 1 101 1 Motorcase

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

102 1 102 1 Valve housing
103 1 103 1 Front cover
104 1 104 1 Valve end cap
105 5 105 5 Cylinder head
201 1 201 1 Crankshaft
202 5 202 5 Piston
203 5 203 5 Connecting rod
204 10 204 10 Piston retaining half ring
205 2 205 2 Con rod retaining ring
206 5 206 5 Restrictor screw
209 1 209 1 Large displacement piston
210 1 210 1 Small displacement piston
212 1 212 1 Spring (displacement piston)
214 214 Front Plate
301 1 301 1 Valve spool
303 1 303 1 Oldham coupling
305 1 305 1 Shim kit (steel)
401 1 401 1 Rear bearing
402 1 402 1 Front bearing
404 5* 404 5* Piston seal ring
405 12* 405 12* Valve seal ring
408 5 408 5 Circlip (piston internal)
410 1* O- 410 1* O-ring (front cover)
413 1* O- 413 1* O-ring (valve end cap)
414 5* O- 414 5* O-ring (cylinder end cap)
415 5* O- 415 5* O-ring (internal ports)
417 * 417 * Shaft seal
418 5 418 5 S.H.C.S (Valve assembly to motor)
419 10 419 10 S.H.C.S. (front cover)
420 45 420 45 S.H.C.S (cylinder head cap)
422 # 422 # S.H.C.S (valve end cap)
426 2* 426 2* Bonded seal, drain
435 2 435 2 Drain plug
452 452 Small piston seal ring
453 1 453 1 Large piston seal ring
474 2* O- 474 2* O-ring (external ports)
476 5* 476 5* Back-up ring (cylinder end cap)
479 2 479 2 Steel plug (valve housing)
482 1* O- 482 1* O-ring (valve housing surround)
483 5* 483 5* Piston seal backing ring
484 1 484 1 Key
485 1 485 1 Washer, long taper shaft
486 1 486 1 Nut, taper shaft
788 1 788 1 Split pin, long taper shaft
50

600 KN Towing Winch Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

600 KN Towing Winch Manual PDF

Uploaded by

Copyright:

Available Formats

600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION

600KN HYDRAULIC TOWING WINCH

Compiled by: Jing Wang

Checked by: MinFang Zhu

Verified by: Yi Chen

Chongqing Lange Machinery Group Co., Ltd.

2. Main Technical Features 3

4. Operation and Use Regulations 5

6. Assembly and Disassembly 7

7. Towing Winch Operation and Use Regulations 2

10. Drawing and main structure 15

11. Electric part drawing 27

12. Marine proportional valve Service Manual 4

13. Swash-plate type Axial piston pump Service Manual 43

14. Hydraulic motors Maintenance Manual 53

3.1 Mechanical Part

with pinion gear fixed on hydraulic motor.

4 Operation and Use Regulations

4.2 Operating Hydraulic Towing Winch

5.2 Maintenance of Operating Valve

5.3 Protection of Hydraulic System

6 Assembly and Disassembly

7. Towing winch Operation and Use Regulations

7.2 Ship towing winch device briefly installation process is as follows

8. Electrical Parts Summary

8.3 Emergency Release

adjust the relief valve set pressure

5.3.6 -10~+60C 65C

Date: 03.05.2005. Rev.0 RECOMMENDED SPARE PARTS

A/S HYDRANOR N-3600 KONGSBERG HIGH QUALITY MARINE HYDRAULICS

Technical data table

FPUHY 3EDU 3EDU /HIWURWDWLRQ 5LJKWURWDWLRQ

Testo5: 80 FLANGE Shaft Testo5: Cover

T.2 = 44.1 [Nm] T.2 = 67.5 [Nm]

CO001 - Tapered CO002 - Tapered

T.2 = 233.2 [Nm] T.2 = 233.2 [Nm]

T.2 = 86.1 [Nm]

Displacement Standard bodies

Technical data table

FPUHY 3EDU 3EDU /HIWURWDWLRQ 5LJKWURWDWLRQ

T.1 = 5458.9 [Nm] - screw tightening torque M10

Testo5: 82.5 FLANGE "SAE A" Shaft Testo5: Cover

T.2 = 44.1 [Nm] T.2 = 67.5 [Nm]

CO001 - Tapered CO002 - Tapered

T.2 = 233.2 [Nm] T.2 = 233.2 [Nm]

T.2 = 67.1 [Nm]

Displacement Standard bodies

B 011 PISTON ASSY 11ST 161(9),162(9)161(9PC).162(9PC)

C 983 PIN COPPER ALLOY 2

C 808 NUT CARBON STEEL 1

C 983 PIN COPPER ALLOY 2

C 774 OIL SEAL FLUORO-RUBBER 1

B 530 TILTING PIN ASS'Y 11ST 631(1),648(1) 631(IPC).648(1PC)

C 983 PIN COPPER ALLOY 2

C 729 2 O-RING NBR 1

B 530 TILTING PIN ASS'Y 11ST 631(1),648(1) 631(IPC).648(1PC)

CLASS. PART No PART NAME Q'TY CONSTITUENT PART No.(Q'TY)

C 983 PIN COPPER ALLOY 2

C 729 2 O-RING NBR 1

14.3 7/16 UNF(PC,PL)

Before disassembling, read all pages of this manual.

When assembling, the order of procedures is the reverse of disassembly.

492 PT1/32 1.5

FPUHY 3EDU 3EDU /HIWURWDWLRQ 5LJKWURWDWLRQ

FPUHY 3EDU 3EDU /HIWURWDWLRQ 5LJKWURWDWLRQ

C 729 2 O-RING NBR 1

C 729 2 O-RING NBR 1

Care should be taken with the small

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