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OPERATION INSTRUCTION
PAGE 1 / 13
600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
CONTENTS
1. General 3
3. Structure Instruction 4
5. Maintenance 7
8. Electrical Component 2
9. Operation Instructions 1
PAGE 2 / 13
600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
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.
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
600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
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.
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.
5.3.5 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.
6.2 Assembly
Assembling procedure is contrary to the disassembling procedure.
PAGE 8 / 13
600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
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
600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
(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
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.
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
600KN HYDRAULIC TOWING WINCH OPERATION INSTRUCTION
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
5.4
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
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
$*
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
+
SCF03 - Splined
Body (threads/flanges)
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
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
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
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
XP219 www.vivoil.com - english 30/06/2008
62
+'&
SCF04 - Splined
Body (threads/flanges)
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
XP219 www.vivoil.com - english 30/06/2008
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
Attached Drawing No.3 K3VL80/A Cross Section
4 K3VL112/A 17
Attached Drawing No.4 K3VL112/A Cross Section
5 K3VL140/A 18
Attached Drawing No.5 K3VL140/A Cross Section
2/ 19
2 Disassembly and Assembly of Pressure Cut-off Load Sensing Regulator
2-1 19
2-1 Tools
2-2 20
2-2 Procedure of Disassembly
2-3 22
2-3 Procedure of Assembly
6 24
Attached Drawing No.6 Exploded Drawing
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
3-2 Procedure of Disassembly
3-3 31
3-3 Procedure of Assembly
9 34
Attached Drawing No.9 Exploded Drawing
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 Procedure of Disassembly
,.
,.
,:
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:
Attached Drawing No.1 Exploded Drawing
Attached Drawing No.2 K3VL45/A Cross Section
Attached Drawing No.3 K3VL80/A Cross Section
Attached Drawing No.4 K3VL112/A Cross Section
Attached Drawing No.5 K3VL140/A Cross Section
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!
1-3 Procedure of Assembly
,,:
(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),.
1 (1) The place must be clean.
(2) Spread rubber sheet, cloth, etc. to prevent parts from
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
Attached Drawing No.1 Exploded Drawing
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
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
SUPPLY CLASSIFHCATION
B PATRS SUPPLIED SUB-ASSEMBLED
( 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
()
CLASS. PART No PART NAME Q'TY CONSTITUENT PART No.(Q'TY)
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 490 PLUG CARBON STEEL 6
C 467 PLUG CARBON STEEL 2
C 465 PLUG CARBON STEEL 1
C 406 HEX.S.H.C.SCREW ALLOY STEEL 4
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 AL ALLOY 1
C 251 SWASH PLATE SUPPORT CAST IRON 1
TIGHTENING TORQUE / 214 TILTING BUSH BEARING STEEL 1
/ 212 SWASH PLATE BUCTILE 1
C 211 SHOE PLATE BEARING STEEL 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
406 M6 12 / 152 SHOE COPPER ALLOY 9
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
490 NPTF1/16 9 C 124 NEEDLE BEARING BEARING STEEL 1
531.532 M22*1.5 240 C 123 ROLLER BEARING BEARING STEEL 1
538 G1/2 110 C 111 DRIVE SHAFT ALLOY STEEL 1
808 M16 130 CLASS. PATR No. PART NAME MATERIAL Q'TY
SUPPLY CLASSIFHCATION
( Th re e B on d1 3 05N )
B PATRS SUPPLIED SUB-ASSEMBLED
App l y a dh es i ve / %CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
( Th r eeb o nd N O . 130 5 N)
C PARTS INDIVIDUALLY SUPPLIED
15
C 538 PLUG ALLOY STEEL 1
C 537 SPRING SEAT CARBON STEEL 1
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
C 490 PLUG CARBON STEEL 6
C 467 PLUG CARBON STEEL 2
C 465 PLUG CARBON STEEL 1
C 406 HEX.S.H.C.SCREW ALLOY STEEL 4
C 402 HEX.S.H.C.SCREW ALLOY 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 AL ALLOY 1
C 251 SWASH PLATE SUPPORT CAST IRON 1
TIGHTENING TORQUE / 214 TILTING BUSH BEARING STEEL 1
/ 212 SWASH PLATE DUCTILE 1
C 211 SHOE PLATE BEARING STEEL 1
TIGHTENING TORQUE
NO. NOMINAL DESIGNATION C 157 CYLINDER SPRING SPRING STEEL 9
OF SCREW THREAD N*m
C 156 SPHERICAL BUSH CAST IRON 1
401,402 M20 440 C 153 SET PLATE ALLOY STEEL 1
406 M8 30 / 152 SHOE COPPER ALLOY 9
465 7/16-20UNF 12 / 151 PISTON ALLOY STEEL 9
1 / 141 CYLINDER BLOCK DUCTILE 1
467 1 /10-12UNF 170
C 127 BEARJNG SPACER CARBON STEEL 2
490 NPTF1/16 9 C 124 NEEDLE BEARING BEARING STEEL 1
531.532 M27*1.5 240 C 123 ROLLER BEARING BEARING STEEL 1
C 111 DRIVE SHAFT ALLOY STEEL 1
538 G3/4 170
808 M20 240 CLASS. PATR No. PART NAME MATERIAL Q'TY
( 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
B PATRS SUPPLIED SUB-ASSEMBLED
/ %CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
C PARTS INDIVIDUALLY SUPPLIED
16
C 538 PLUG ALLOY STEEL 1
C 537 SPRING SEAT CARBON STEEL 1
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
C 490 PLUG CARBON STEEL 6
circumierential serface
C 467 PLUG CARBON STEEL 2
C 465 PLUG CARBON STEEL 1
C 406 HEX.S.H.C.SCREW ALLOY STEEL 4
C 402 HEX.S.H.C.SCREW ALLOY STEEL 1
C 401 HEX.S.H.C.SCREW ALLOY STEEL 4
/ 313 VALVE PLATE ALLOY STEEL 1
C 312 VALVE COVER DUCTILE 1
C 271 PUMP CASING CAST IRON 1
C 261 SEAL COVER AL ALLOY 1
C 251 SWASH PLATE SUPPORT CAST IRON 1
TIGHTENING TORQUE / 214 TILTING BUSH BEARING STEEL 1
/ 212 SWASH PLATE DUCTILE 1
C 211 SHOE PLATE BEARING STEEL 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
401,402 M20 440
C 153 SET PLATE ALLOY STEEL 1
406 M8 30 / 152 SHOE COPPER ALLOY 9
465 7/16-20UNF 12 / 151 PISTON ALLOY STEEL 9
1 / 141 CYLINDER BLOCK DUCTILE 1
467 1 /10-12UNF 170
C 127 BEARJNG SPACER CARBON STEEL 2
490 NPTF1/16 9 C 124 NEEDLE BEARING BEARING STEEL 1
531.532 M27*1.5 240 C 123 ROLLER BEARING BEARING STEEL 1
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
Mark means that the tool
is required.
Tool name and size Part name
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
Adjustable ,1
single Medium size, 1 piece
wrench
,2
Screw driver Medium size, 2 pieces
,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
2-2 Procedure of Disassembly
,.
,.
,:
6
7 KR3L-**
8 KR3B-**
18
!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.
(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
2-3 Procedure of Assembly
2
2
(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.
(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.
20
!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.
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 - * *
SUPPLY CLASSIFICATION
23
&PARTS INDIVIDUALLY SUPPLIED
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 - * *
SUPPLY CLASSIFICATION
24
, .
Apply assemble oil before inserting the spool into the casing. &PARTS INDIVIDUALLY SUPPLIED
Confirm that the spool moves smoothly.
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
Mark means that the tool
is required.
Tool name and size Part name
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
Screw driver Medium size, 2 pieces
,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
3-2 Procedure of Disassembly
,.
,.
,:
9
10 KR3*-**
26
!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.
(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
3-3 Procedure of Assembly
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.
(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.
29
!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.
,, (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
Attached Drawing No.9 Exploded Drawing
32
To be assembled
With the groove outside
10 KR3*-* *
A A
Attached Drawing No.10 Cross Section KR3* - * *
33
SUPPLY CLASSIFICATION
&PARTS SUPPLIED SUB-ASSEMBLED
%CONSTITUENTS OF B (NOT INDIVIDUALLY SUPPLIED)
&PARTS INDIVIDUALLY SUPPLIED
4-1
,.,.
(-,-)
standard of initial value / standard of limit for replacing
Measuring item Measure
45 80 112 140
(: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.
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
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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
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STAFFA Overhaul & Maintenance manual
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]
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STAFFA Overhaul & Maintenance manual
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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]
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STAFFA Overhaul & Maintenance manual
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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
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
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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
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5
!Restrictor Screw Identification
11 Nm (8 lbs/ft)
loctite542
All restrictors must be sealed around their thread using thread locking fluid.
(Suitable fluid, would be loctite 542.)
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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.
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7
Hydraulic Motor
Fault Possible Causes Remedy
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.
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.
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8
Hydraulic Motor
Fault Possible Causes Remedy
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
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9
(6) B7*
(6) DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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10
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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11
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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).
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12
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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13
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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).
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14
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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15
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
21/
PREPARATION BEFORE 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.
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MOTOR
16
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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
Fig 13.
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17
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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18
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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MOTOR
19
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
'X'
'C'SPACER MOUNTING
FACE.
MOTORCASE
Before turning the motor, the bearing cup should be fitted into
REAR BEARING
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.
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MOTOR
20
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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MOTOR
21
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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
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MOTOR
22
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
IWOEV
PP
PP
PPPPPP
Fig 22.
Fig 23.
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23
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
$
%
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.
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24
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
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.
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25
B7*
DISASSEMBLY OF B TYPE 7* SERIES MOTOR.
Fit all gauge plugs and all case drain plugs with new seal
washers.
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26
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
3/
REMOVAL OF CYLINDER END CAPS.
Ensure that the two screws are
tightened evenly as the front cover
is removed from the motorcase.
Fig 29.
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27
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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28
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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).
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29
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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30
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
Fig 32.
Remove the valve seal rings from the valve spool.
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31
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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32
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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MOTOR
33
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
22/
ASSEMBLE DRUM & BEARINGS TO SHAFT.
Check that all oil galleries are clean.
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.
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34
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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MOTOR
35
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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36
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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37
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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38
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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39
C7*
DISASSEMBLY OF C TYPE 7* SERIES 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.
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40
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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
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41
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
53
Fig 53.
54
Fig 54.
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42
C7*
DISASSEMBLY OF C TYPE 7* SERIES MOTOR.
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.
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43
REQUIRED TOOLING.
))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).
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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
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
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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
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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
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
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47
B7*
COMPONENT IDENTIFICATION LIST FOR B 7* SERIES MOTOR .
!!!!! Jufn!!Ruz/!!Eftdsjqujpo!
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
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STAFFA Overhaul & Maintenance manual
MOTOR
49
B7*
COMPONENT IDENTIFICATION LIST FOR B 7* SERIES MOTOR .
!!!!! Jufn!!Ruz/!!Eftdsjqujpo!
50