Om-02 Deck Machinery PDF

SAFETY PRECAUTIONS
Before you use the product, you MUST read the instruction book and
MUST fully understand how to use the product.
To use the product safely, you MUST carefully read all Warnings and
cautions in this manual.
1. Warning and Cautions for operation
(1) △
! WARNING Make it sure that no one is near the windlass, the
winch, or the cylinder before you start operating.
(2) △
! WARNING Never touch the moving part such as drum,
Rope and chain during the operations.
(3) △
! WARNING Never remove the protection cover over the
rotating part of the pump shaft to avoid injuries caused by
being rolled fingers or cloths in.
(4) △
! WARNING Stop the operation immediately if you find
something wrong such as unusual noise, oil leakage
and smoke, and fix it properly. If you continue
operating, you may encounter damage, fire or injury.
(5) △
! CAUTION Keep your body off the product during the
operations as it may become hot and burn your
body.
(6) △
! CAUTION Put on the brake immediately after operation.
If the brake is left off, the anchor may be dropped
and/or the hydraulic motor may be damaged.
(Especially, this could cause serious damage to the
con rod assembly, retaining ring, valve housing,
Oldham’s coupling, distributor valve spool of hydraulic motor)
(7) △
! CAUTION Operating the windlass carefully not to apply
excessive external force when using it in bad
weather, otherwise the hydraulic motor may be
damaged.
(Especially, this could cause serious damage to the
con rod assembly, retaining ring, valve housing,
Oldham’s coupling, distributor valve spool of hydraulic motor)
(8) △
! CAUTION Use the proper hydraulic oil, and maintain the
contamination in the level described in the
instruction book, otherwise it may not work or be
damaged.
(9) △
! CAUTION Be sure to insert the pin and fix the clutch lever,
after operating the clutch. If the pin is off, you may
encounter damage or injury.
(10) △
! CAUTION At anchoring with clutch disengaged, the chain
drum should be operated with the holding load
controlled and sustained by applying the brake at
about each half shackle of the chain.
Otherwise it will cause the anchor and anchor
chain lost by flying out violently, and this is liable
to lead to an injury.
2. Warning and Cautions Related to Maintenance
(1) △
! WARNING Make it sure that the power of the hydraulic pump unit is
turned off and that the electric motor has completely
stopped before starting maintenance. You must also check
the system pressure has dropped to zero.
(2) △
! CAUTION Maintenance must be done by a person with enough
knowledge.
(3) △
! CAUTION Expel air from the circuit completely and fill the
hydraulic motors and pumps with oil before
restarting them after disassembling.
3. Warning and Cautions when heave in chain
NO GOOD
△
! CAUTION
Avoid too high tension in chain when heaving.
If the chain load exceeds the winch max. capacity, it can cause severe damage to
the hydraulic motor.
(Especially, this could cause serious damage to the con rod assembly, retaining
ring, valve housing, oldham’s coupling, distributor valve spool of hydraulic motor)
GOOD
△
! CAUTION
IMMEDIATELY AFTER USE, TIGHTEN THE BRAKE
△
! CAUTION
Never try to haul a vessel against current or wind as the pulling capacity will be
too small. Use the propeller and main engine to reduce chain tension.
otherwise the hydraulic motor may be damaged.
△
! CAUTION (IACS UR A1.1.2)
The equipment is therefore not designed to hold a ship off fully exposed coasts
in rough weather or to stop a ship which is moving or drifting. In this condition
the loads on the anchoring equipment increase to such a degree that its
components may be damaged or lost owing to the high energy forces generated,
particularly in large ships.
△
! CAUTION (OCIMF Anchoring systems and procedures)
Mariners should be aware that windlasses are typically designed to lift a maximum
weight of an anchor and three free-hanging shackles(shots) of cable.
△
! CAUTION (OCIMF Anchoring system and procedures)
When walking-out the anchor by means of the windlass motor, it is important
that the vessel’s speed over the ground is less than the walking-out speed,
which is typically 9meters/min, equivalent to less than 0.3knot. Higher speeds
over the ground may cause the motor to render.
INDEX
CHAPTER 1. INTRODUCTION
PREFACE
STORAGE INSTRUCTIONS FOR DECK MACHINERY
CHAPTER 2. SPECIFICATION & DRAWING

2-1. RULES ……………………………………………………………………………1
2-2. EQUIPMENT LIST…………………………………………………………………1
2-3. PARTICULARS ……………………………………………………………………4
2-4. MATERIALS OF MAIN PARTS ………………………………………………… 6
2-5. SPARE PARTS AND SPECIAL TOOLS…………………………………………6
2-6. PAINTING…………………………………………………………………………7
2-7. HYDRAULIC FLUID AND LUBRICANTS………………………………………7
2-8. DOCUMENTS TO BE SUBMITTED……………………………………………8
2-9. NAME PLATES……………………………………………………………………8
2-10. GUARANTEE ……………………………………………………………………8
2-11. SHOP TEST PROCEDURE …………………………………………………9
2-12. DRAWING
(1) WINDLASS ………………………………………………………………… 10
(2) BELL MOUTH …………………………………………………………… 16
(3) MOORING WINCH ………………………………………………………… 16
(4) CHECK VALVE………………………………………………………………28
(5) STOP VALVE……………………………………………………………… 29
2-13. LIST OF SPARE PARTS AND TOOLS ……………………………………… 30
2-14. ALIGNMENT FOR MAIN SHAFT(WINDLASS) ……………………………… 54
2-15. PIPING STANDARDS ………………………………………………………… 70
CHAPTER 3. INSTRUCTION FOR OPERATION
3-1. OPERATION NOTES
3-2. OPERATION OF WINDLASS
3-3. OIL CHARGING AND AIR EXPELLING
3-4. PRELIMINARY OPERATION
3-5. OPERATION OF WINDLASS AND MOORING WINCH
3-6. CAUTIONS
3-7. ADJUSTMENT OF THE HYDRAULIC EQUIPMENT
3-8. STOPPER FOR LEVER OF CONTROL VALVE FOR WINDLASS
CHAPTER 4. INSTRUCTION FOR MAINTENANCE AND CHECKING

4-1. MAINTENANCE MANUAL (DIGEST)
4-2. MAINTENANCE FOR THE GEAR
4-3. WORKING OIL AND LUBRICATION OIL
4-4. WINDLASS, WINCH, HYDRAULIC MOTOR, CONTROL VALVE AND PIPING
MATERIALS
4-5. OTHERS
4-6. INSTRUCTION FOR REPLACING THE BRAKE LINING OF BOLT-NUT TYPE
4-7. MAINTENANCE ON FAILURE OF HYDRAULIC WINCH
CHAPTER 5. TROUBLE SHOOTING LIST
CHAPTER 6. DETAIL DESCRIPTION OF MAIN PARTS

6-1. HYDRAULIC MOTOR
6-2. COUNTERBALANCE VALVE
6-3. CONTROL VALVE
6-4. REGULATOR FOR HYD. MOTOR
6-5. FAIL-SAFE BAND BRAKE
CHAPTER 7. ASSEMBLY DETAIL

INSTRUCTIONS MANUAL
CHAPTER 1.
INTRODUCTION
COPYRIGHT FLUTEK, LTD

INSTRUCTIONS MANUAL
PREFACE
We take pleasure in expressing our sincere thanks you for purchasing of our deck
machinery. This instruction book covers the explanation of maintenance and
instruction for deck machinery. These instruction are intended for the shipyard’s
crew and Start-up of deck machinery on ships.
The right operation and pertinent inspection and periodic maintenance
provide the highly quality and safety machine for you.

INSTRUCTIONS MANUAL
STORAGE INSTRUCTIONS FOR

DECK MACHINERY
1. Receiving inspection
On arrival to the yard, all of the packages have to be inspected visually in order to
check transport damages.
Any damaged packages or equipment shall be reported to contactor at FLUTEK,Ltd.,
not later than 7days after receiving.
2. Storage place
- Dry and level bottom.
- Well-drained.
- Well-ventilated indoor storage.
- no vibration.
3. Store air
- relative humidity max. 75%
- dust free
- no corrosive gases
4. Temperature
- must be over 10˚C
- fast variations in temperature must be avoided.

INSTRUCTIONS MANUAL
5. Long-term equipment storage strategy

Generally, all equipment and package to be stored in doors in a dry and flat
room with above temperature condition.
If equipment are stored over six months, should be paid special attention.
- Equipment Storage must be kept the above conditions.

- Broken packing must be repaired.
- It must be ensured that humidity have not penetrated.
- Exposed Shafts, brake spindles, open gear, machining surface, etc. have to be
carefully stored after visual inspection.
- Electric and electrical equipment must be taken care of by e.g. silica gel bags.
- Equipments must not be stored one upon another.
- Electric equipment and device such as starter panel, Junction box and R.P.B must be
stored at least 1 meter from the floor level.
The following inspections and services must be made every three months:
- check if humidity has been condensed inside package
- if it has package is to be opened, dried and recovered.
- if it is broken, repair packages.
6. Unpacking
- Carefully remove all packing parts
- Packages are removed only when installation begins.

INSTRUCTIONS MANUAL
CHAPTER 2.
SPECIFICATIONS & DRAWING

7
6. PAINTING
NAME OUT-DOOR IN-DOOR
S1138 / 39 / 65 / 66
Alkyd resin zinc chromate and iron

Sigmaprime 700 (Gray)
Under coating oxide primer
----------- 175 μm x 1
--------- 2coats (35 μm x 2 )
Alkyd resin enamel

Finish coating & Sigmacover 456 (R/Brown(CSC2027)
--------- 1coat (35 μm x 1)
Finish color ------------ 125 μm x 1
Not yet decided Finish color
S1140 / 41 / 42 / 43 / 44 / 45 / 46 / 47 / 50 / 51 / 67 / 68 / 69 / 70 / 5120 / 5121
Alkyd resin zinc chromate and iron

Bannoh 2000 (Gray)
Under coating oxide primer
----------- 175 μm x 1
--------- 2coats (35 μm x 2 )
Alkyd resin enamel

Finish coating & Epicon Marine HB (R/Brown(CS-511)
--------- 1coat (35 μm x 1)
Finish color ------------ 125 μm x 1
Not yet decided Finish color
Paint maker Refer to Yard paint Spec.
Detail method Manufacturer's standard
7. HYDRAULIC FLUID AND LUBRICANTS

QUANTITY
KIND OF OIL
FORE AFT
JIS K 2220 Gear compound For one lubrication

Open gear
Class 1, No.2 or equivalent
abt. 3kg
JIS K 2219 Gear oil Class 2, For one lubrication

Enclosed gear
ISO VG220 ~ 320 or equivalent
abt.75x7=525L
JIS K 2220 Grease Concentric For the first lubricating

Bearing metal
oil supplied type
and linkage
Class 4, No.2 or equivalent
abt. 10kg
* Contamination:NAS 1638 Class 9 (ISO 4406-/18/15 equivalent)
* Proper viscosity to use : 25cSt ~ 200 cSt

30
LIST OF SPARE PART AND TOOLS

OF
ELEC.-HYD. DECK MACHINERY
HULL NO. : S1138/39/40/41/42/43/44/45/46/47

1150/51/65/66/67/68/69/70,5120/21
MESSER'S. FLUTEK, LTD

MARINE MACHINERY WORKS
DIRECTOR
1. SHIPYARD : SPP Shipbuilding Co., Ltd.
2. Hull No. : S1138~47, 1150, 1151, 1165~70, 5120, 5121 GENERAL RESEARCH
3. OWNER : SCORPIO SHIP MANAGEMENT S.A.M ENGINEER
4. KIND OF SHIP : 49,990 DWT Product Oil/Chemical Tanker CHIEF RESEARCH
5. CLASSIFICATION : DNV ENGINEER
RESEARCH
ENGINEER C.W.RYU
DRAWING NO. : FMW45-4128 DATE : 2013. 06. 03
F L U T E K, Ltd.
67
INSTRUCTIONS MANUAL
LIFTING GUIDANCE – Cable lifter unit

1. Preparation and line of action
- The cable lifter is delivered in one unit

- The unit has four eye plates for lifting. (See Fig.1 or 2 according to layout)
- Fasten a wire to each lifting eye plate and adjust the wire lengths to get a good balance
and a horizontal lift.
- Make sure the wire has sufficient strength to carry the winch.
- The weight can be found in the weight specification on each package.
2. Important
- Remember always to put safety first.
Fig.1
Fig.2
1/3
68
INSTRUCTIONS MANUAL
LIFTING GUIDANCE – Mooring winch (One drum)

- The winch is delivered in one unit, with gear and one drum.
- The gear box has two lifting eyes which should be used.
- A wire/rope must also be wrapped around the drum(See sketch), and located on the drum
to get a good balance.
- The length of the wire must be adjusted in each case to get a horizontal lift.
- Make sure the position of the wire do not causes damage on any part of the winch.
2. Important
- The system contains hydraulic oil which will pollute the environment if spilled.
2/3
69
INSTRUCTIONS MANUAL
LIFTING GUIDANCE – Mooring winch (Two drum)

- The winch is delivered in one unit, with gear and one drum.
- The gear box has two lifting eyes which should be used.
- A wire/rope must also be wrapped around the drum(See sketch), and located on the drum
to get a good balance.
- The length of the wire must be adjusted in each case to get a horizontal lift.
- Make sure the position of the wire do not causes damage on any part of the winch.
2. Important
- The system contains hydraulic oil which will pollute the environment if spilled.
3/3
70
PIPING STANDARDS
Publication October 1961

1st revision March 1966
(Piping material approved by JIS)
2nd revision July 1970
(Amendment in piping process)
3rd revision May 1971
th
4 revision January 2008
MARINE MACHINERY DIVISION

FLUTEK, LTD
1
Contents
1. prefaces ----------------------------------------------- 2
2. preparation ----------------------------------------------- 3
2-1 Preparation of piping material ------------------------ 3
2-2 Identification before start of piping --------------------- 3
3. Pipe work ------------------------------------------------ 4
3-1 Pipe cutting ------------------------------------- 4
3-2 Joint working ------------------------------------- 5
3-3 Molding of pipe ----------------------------------- 6
3-4 Fitting of accessories ------------------------------- 7
4 Pressure proof test ------------------------------------------ 8
4-1 Test procedure ------------------------------------ 8
4-2 Test time ---------------------------------------- 8
5 Cleaning of the interior of pipe --------------------------------- 8
5-1 Mechanical cleaning -------------------------------- 9
5-2 Chemical Cleaning --------------------------------- 9
5-3 Oil flushing --------------------------------------- 13
5-4 Cleaning of the interior of the tank ---------------------- 16
6 Fitting of pipe ---------------------------------------------- 17
6-1 Fitting of pipes ------------------------------------ 17
6-2 Anchoring ---------------------------------------- 17
7 Test operation --------------------------------------------- 17
2
1. Preface
This pamphlet describes operation standards for piping connecting various devices
composing the oil standard the oil pressure device and it is the purport to make each of the
machines display its full function.
Generally, the piping for hydraulic equipment will be conducted in the following order:
Limited to the necessary parts for field assembly
Modeling For other parts, modeling is not given and follows the
working drawing.
(1) Follow the working drawing.
Cutting (2) Those modeled for field assembly, are bent and cut
according to the model and the joints are fit to the
devises and they are welded temporarily. And then,
Joint welding
they are detached and are welded formally.
Bending Working order may seem to be simple. But, if correct

operation is not given in the actual work, it may cause
disorder of the hydraulic equipment and they may not be
Pressure able to fulfill their functions effectively. Therefore, do not
proof test conduct any operation other than mentioned in this
pamphlet unless specially instructed.
Mechanical
cleaning
Chemical
cleaning
Pitting
3
2. Preparation
2-1 Preparation of piping material
(1) Regular material must be used for piping.
Whether it is purchased or stock, they must be standardized goods. Since there is
difference in the quality of material or the thickness according to the working
pressure, the material items must not be mixed and it is also necessary to keep
them in different storages and classify them by making.
(2) Joints (elbow, reducer and others) must be inserting weld types.
(3) Material must be clean .
Avoid dirty material with rust and dust on the surface. Especially, when the interior is
badly stained the pipes must be washed by chemicals before working.
Chemical washing
In case of the varnished interior :
Varnish removing rinsing deoiling rust moving neutralization rinsing drying
In case of oily dust :
Deoiling rust moving neutralization rinsing drying.
In case of only rust :
Rust moving neutralization rinsing drying.
2-2 Identification before start of piping.

(1) Oil hydraulic equipment must be fixed on the stable mount. Pay attention not to give
unreasonable weight on the joints between the pipes and the devices in order to
prevent the pipes and joints from breaking and to make the device work smoothly.
For the purpose, the piping work must be started after the device is firmly fixed and
the device must not be supported by piping.(except the in-line check valves and
others).
(2) The anchor for fixing pipes must be placed in the prescribed position.
(3) Blank cap must be put to prevent dust from entering the oil hydraulic equipment.
Confirm every blank cap on every opening before start of the work because, if dust
enters inside the equipment it causes trouble.
As shown in the drawings, the blank cap is equipped with metal plate, vinyl plug, and
others.
Do not put an inflammable blank cap on the upward opening. It is also necessary to
confirm the blank cap firmly fixed on the opening when the joints are detached for
piping work.
When the device is placed outdoor or in the place where water drops fall, it must
4
completely covered by vinyl sheet.
3. Piping work
Fix the position of joints and bends in order to make fitting and detaching of pipes
easy.
This is also important for maintenance and inspection of the oil hydraulic equipment
and repairing oil leaking.
Pipe work processes are divided into three categories according to the working places
and each has different working order.
Working
Semi-assembly in plant
place Inside plant
Final assembly in field
Order
Cutting Cutting Molding
1
(including Marking-off) (including Marking-off)
2 Joint welding Joint welding Cutting
3 Molding Molding Joint welding
-- (after this) --
4
Field cutting
5 -- Welding --
3-1 Pipe cutting

(1) Marking-off in accordance with the working drawing in the prescribed length.
(2) Make cutting according to working drawing.
Use cutting grinder or saw for cutting but do not use gas cutting apparatus.
It is necessary to do cutting so as to make the cutting plane a right angle with pipe.
In case of necessity of gas cutting, the cutting plane and the surrounding part must
be finished by a grinder or a file, and spatters, scales and slags must be removed
completely.
(3) Return scraps of the cutting plane must be removed completely.
(4) The butt resistance weld part must have a V-shaped
beveling on its one side at about 37˚ as is shown in the
right drawing.
5
Union and butt welding pipe joints (elbow and cheese)

have bevels and there is no need of making new beveling.
3-2 Joint welding

(1) Welding rod, pipe diameter and weld layer must correspond to the following table.
Table for standard welding rod:

Diameter
Thickness 1/8B – 3/4B – 2B – 3 1/2B –
Filing
Of pipe 1/2B 1 1/2B 3B 5B
Frequency
More than Tack weld (A) 2.6 ϕ (A) 2.6 ϕ (A) 2.6 ϕ (A) 2.6 ϕ
st
Schedule 1 layer (B) 2.6 ϕ (B) 3.2 ϕ (B) 3.2 ϕ (B) 3.2 ϕ
80 2nd layer / / (B) 4 ϕ (B) 4 ϕ
rd
3 layer / / / (B) 4 ϕ
Finishing / (C) 3.2 ϕ (C) 4 ϕ (C) 4 ϕ
Less than Tack weld (A) 2.6 ϕ (A) 2.6 ϕ (A) 2.6 ϕ (A) 2.6 ϕ
st
Schedule 1 layer (A) 2.6 ϕ (A) 3.2 ϕ (A) 3.2 ϕ (A) 4 ϕ
40 2nd layer / / / (A) 4 ϕ
SGP finishing / / (C) 3.2 ϕ (C) 4 ϕ
Notations and Brands

Kawasaki Nippon
MARK Standard Kobe Steel Ltd.
Steel Corp. Steel Corp.
G-200
A JIS D4301 KS-8 B-17
Or (A-100)
B JIS D5016 KS-78 LB-52 (S) L-55
C JIS D4313 KS-R B-33 (S)-12
(2) Pipe joints (elbow, cheese, flange or union) must pressed on the joint parts of the pipes
and prevent from becoming dusty. But, as shown in the drawings, in the case of the
flange in which the inserting pipe with the same diameter is intruding into the other pipe,
the pipe should not go over the flange surface.
(3) Flange must be fixed in the right angle with pipe.
(4) Butt welding of pipe to pipe is prohibited. If necessary, do fillet weld by using socket.
But in this case, the thickness of socket must be endurable to the working pressure.
(5) Pipe joints are generally inserting type. If you use butt welding, you must place the
6
flange nearby and remove beads, spatters and scales from inside the pipe.
(6) For branch part, cheese or T-type flange fitting are used. Do not conduct butt
welding by making holes on the pipe by a gas cutter. If necessary, place nearby and
clean the interior thoroughly after welding.
3-3 Piping molding

(1) Piping must be carried so as not to give unreasonable weight on the device.
The pipe must be shaped so that it does not deformed and unreasonable weight will not
given on the device according to the changes in the pressure or the temperature.
(2) The joints (flange or union) must be fixed so that fitting and detaching of pipes or the oil
hydraulic equipment can be carried out easily. Do not connect more than three devices
with one pipe.
In this case, make joints in the middle to make fitting and detaching easy.
7
(3) When you thread the pipe (cone screw) and screw it into the internal thread directly, you
must put the flange or union nearby so that you can fit it or detach for maintenance.
(4) The length of the pipe which is directly connected with device, should be 1 or 2 meters.
It is necessary to make pipes short so as to make the maintenance of the device simple
and easy.
(5) For bending, pipe bender must be used in cold temperature. Heat bending must be
avoided. If it is unavoidable, it must be carried out as near as possible to the flange and
the interior must be cleaned by grinder, wire brush or file and confirm that all spatters,
scales and dust are removed.
(6) Bending must be carried out in the nearest place to the flange.
(7) The pipe must be processed so as not to be deformed or to cause wrinkles.
(8) In bending steel pipe or gas pipe, the radius (R ) of the bend is more than three times
longer than the diameter of the pipe (d) .
(9) Piping must be carried out so that one pipe does not contact with the other.
(10) Each pipe must be manufactured in the size which can enter the chemical washing tab
(for acid bathing, neutralization) and is convenient for transportation.
(11) Pipes must be arranged in right angle or in parallel the device or building so as not to
spoil the beauty.
3-4 Fitting of accessories

(1) To extract air from inside the pipe, the air-bleeder must be installed at the upper part of
the piping. This must be installed especially on the suction pipe unless special cares are
taken.
(2) The adaptors for the thermometer and manometer must be fixed near the flange.
(3) After welding of the adaptor, a hole is drilled on the pipe and return scraps must be
removed completely.
8
(4) It is desirable that drain plugs is installed in its lower part to extract oil stains from inside
the pipe.
4. Pressure proof test

As a rule, the pipe in which maximum working pressure exceeds 50 kg/cm^2, undergoes
hydraulic test.
If there is leakage, it must be repaired carefully.
4-1 Test pressure
Unless otherwise instructed, the test pressure follows the following standard:
When the maximum working pressure is less than 70 kg/cm^2 :
The maximum working pressure × 2
When the maximum working pressure is over than 70 kg/cm^2 :
The maximum working pressure + 70 kg/cm^2
4-2 Test time
Time of test pressure maintenance is 10 minutes.
5. Cleaning of the interior of pipe

It is assumed that most of the troubles of the oil hydraulic equipment are attributes to
the refuse. To prevent troubles, the interior of the pipes must be cleaned thoroughly in
order to make the oil hydraulic equipment work smoothly. Kinds of the foreign matters
within the pipe and the cleaning methods are shown in the following table:
Cleaning
Tube Acid Oil Chemical
Kind of Method grinder hammering
cleaner washing flushing flushing
foreign matter
Return scraps ◎ △ × × × ×
Rust ○ ○ △ ◎ × ◎
Scale ◎ ○ △ △ × ○
Weld slag ◎ ○ △ × × ×
Spatter ◎ ○ △ × × ○
Floating matter × × × × ◎ ◎
◎:Greatly effective, ○:Effective, △:A little effective, ×:Not effective
9
As shown in the table, various cleaning methods must be applied together in order to
extract all kinds of the foreign matter.
Each of the cleaning methods is explained later and the best order of applying the methods
will be : grinder (tube cleaner), chemical flushing (combined use with hammering), and oil
flushing (combined use with hammering).
5-1 Mechanical cleaning (by grinder, tube cleaner or other), removes spatters, scales or
rust in the pipes.
(1) The part around the flange is cleaned by grinder.
(2) The deeper part or the bend which cannot be reached by grinder, is cleaned by using
a tube cleaner or a wire brush with a long handle.
5-2 Chemical cleaning (acid washing, chemical flushing, etc.)

(1) Soaking method
(a) The working order is as follows:
In case of varnish sticking inside the pipe:
Removing varnish  rinsing  deoiling  removing rust  neutralization and rust
proof.
In case of oil sticking inside the pipe:
Deoiling  removing rust  neutralization and rust proof.
When there is only rust inside the pipe:
Removing rust  neutralization and rust proof.
(b) Treatment liquids and soaking time will be as attached table.
(c) During the soaking, be careful not to cause air pocket inside the pipe. If there is air
pocket, drive it out by shaking or reversing the pipe.
(d) In the final process, rinsing must be given fully and removes residual liquid and
foreign matters.
For rising, always use running water sufficiently.
Do not use a water bath. If possible, use the pressurized hot water to wash off the
treatment liquid sticking to the inside of the pipe and to quicken the drying with
the heat of the hot water.
(2) Circulation method (chemical flushing)
The soaking method has several problems as follows:
It takes time because the chemical liquid does not move from the surface of the metal
10
to be cleaned; the pipes may not be able to enter the tab which is not large enough; it
may cause residual air inside the pipe making the cleaning partial and insufficient. The
circulation method supplies the deficiencies of the soaking method and is also
effective in removing the foreign matters after mechanical cleaning.
The operation of the circulation method can be carried out with the following facilities
and means (treatment liquid and treatment time are described in the attached table).
(a) Pump, motor, valve and other devices within the circuit are removed and they are
connected with other pipes. This temporary piping can be used for oil flushing
which will be given later. In another method, only piping are detached from the
system and assembled in one line in the other place.
(b) Connect with the chemical flushing unit. The system of the chemical flushing unit will
be as is shown in the following drawing, and it must have the capacity indicated in
the following :
Pump 1: It must resist the pressure of
5 - 10 kg/cm^2 with the flow rate
Of 2 – 5 m/sec.
And acid proof and alkali
Resistance.
Filter 2: To be installed on the discharge

side of the pump. It is desirable that it is more than 200 mesh and can resist
the working pressure of 5 – 10 kg/cm^2. If you confirm that abrasion powder
of the pump is not mixed into the chemical liquid being sent from the pump,
you do not have to use this filtering.
Filter 3: This is installed on the return line where the foreign matters are detected and
11
preparation is made for flushing. Filter can be any type as far as it is a wire-
netting type. The mesh of the wire-net is 60, 100, 150, or 200 according to
the occasion.
Tank 4: This is deoiling liquid tank and its capacity is 1.5 – 2 times the discharge
volume per minute of the pump.
Tank 5: This is rust-removing liquid tank and its capacity is that of Tank 4. But its
material must not be affected by the rust-removing liquid.
Tank 6: This is rust-proof liquid tank and its capacity is that of Tank 4.
Notes) You can carry out cleaning using only Tank 5 by exchanging the liquid every time.
(c) Drive the flushing pump and send deoiling liquid for 10 to 30 times.
(d) Change deoiling liquid to fresh water and rinse for 10 to 20 minutes. The return water
is discharged directly to the drainage.
(e) Change it to the rust-removing liquid and pump for 60 to 120 minutes. During the
pump operation, give some shocks from outside (hammering) to shake off the scales
and others inside the pipe.
In this case, the net of the filter is first 60 mesh and check the net in every 30
minutes and change to finer net one by one. The final judgment is given when you
don`t recognize any foreign matter with the naked eyes after the rust-removing liquid
is flushed through the 200-mesh net. Therefore, the above-mentioned filtering time
is not sufficient, you can further extend the time.
(f) Rinse for 20 to 30 minutes by fresh water.
(g) Pump rust-proof liquid for 10 to 20 minutes.
(h) In the final stage, detach the chemical flushing unit from the pipe, and extract the
residual rust-proof liquid in the pipe by detaching the joint near.
(i) In carrying out (c) – (g), in the first place, make the branch pipes blank. A part
drawing of page 14 and make the main pipe blank making the liquid flow to the
branch pipe.
(j) Then carry out oil flushing.
12
Attached Table : Chemical Cleaning Methods and Liquids

General Neos Coolmin Rasatol Treatment method
Coolmin NR,
Liquid Soaking or
“Coolmin circulation NR,
k-100, for 60 min.
Varnish
2-3 times k-100 for 180 min.
removing
acqueous
solution Heating(60 – 80˚C) is
(combined with desirable.
deoiling)
Caustic soda 5- Soaking or circul-

Neos CM
10% aqueous ation 10-30 min.
100 Coolmin
Deoiling solution Caustic soda CM 100
3-5% E105
Kerosine is heated.
solution
Trichlorethylene
Injection by pressurized water, pressurized hot water and high-pressure steam.

Rinsing Washing by running water and not by water bath. In case of kerosine or
trichloroethylene, there is no need of rinsing.
Hydrochloric Neos
Rasatol
acid 10-20% CM 305 Coolmin Soaking or circul-
Rust #200 2-
solution Sulfuric 2-5 E 30S ation 60-120 min.
removing 3 time
acid 5-10% time 30-50% solution
solution
solution solution
Injection by pressurized water, pressurized hot water and high-pressure steam.
Rinsing
Washing by running water and not by water bath.
Soaking or cir-
Neutraliz Neos CM culation 1-2 min. for
Coolmin #0 Rasatol
ation, Caustic soda 5- 306 3- caustic sada.
5-10% #300
Rust 10% solution 5% Soaking or cir-
solution solution
proof solution culation 2-5 min. for
others
Rinsing,
drying
13
Work oil
Extract excessive rust-proof liquid inside the pipe after rust-proof treatment and
leave it for a while, after warping both ends for the pipe to prevent the foreign
After matter entering the pipe, by slion tape or polyethylene sheet. This rust-proof
treatment treatment is effective only for a few days.
Therefore, you must move to the next operation of oil flushing as quick as
possible.
5-3 Oil flushing

Oil flushing is carried out in the final stage to eradicate the fine foreign matters from
inside the pipe after cleaning the new pipes before pipe fitting completely.
(This is also used for extracting the microscopic matters or oil sludge from inside the
pipe)
This treatment can be avoided if the pipe is simple and short and you can see the
inside through the entrance.
But this treatment is given when one of the piping which form one system (the pipe
between one device to the other, except in-line check valve), is longer than following
standard or the number of pipes exceeds the following:
Pipe diameter: 3/4B ~ 1-1/4B : 5m or over 1/5
1-1/2B ~ 3B : 3m or over 1/5
Oil flushing will be carried out as follows:
(1) Detach the pump, motor, valve and others and joint them with other pipes for
temporary piping. If the valves such as directional control valve are not detached,
you must open and check the inside of the valve after flushing treatment.
Otherwise, detach only the pipes from the system and joint them in one line in
other place.
If it is difficult to detach the devices, detach pipes directly connecting with the
devices and make a bypass by temporary piping.
14
(2) connect with flushing pump.

Flushing device is shown in the right drawing.
Each device must be equipped with following capacities:
Pump 1: Discharge volume is at least 1.2 times the normal maximum flow rate of
the hydraulic power unit with 5-10 m/sec of velocity of flow inside the
discharge pipe. Discharge pressure differs according to the pipe length
and velocity of flow inside the pipe, but it shall be 30-50 kg/cm2
Strainer(Suction line) 2: This protect pump 1 and according to the kind or type of
the pump, a mesh of 60-150 is necessary.
If the inside of the tank is completely cleaned and the cap is perfect, this
can be avoided.
Filter(return line) 3: Detect the foreign matters sticking to this filter and control the
cleaning condition inside the piping which from a oil hydraulic power unit.
In the operation, you change filters one by one from the coarse mesh to
fine mesh. Therefore, you need the filters from 60-100 mesh to 200 mesh.
Filter(discharge line) 4: This prevents the matters such as abrasion powder from
entering the oil hydraulic power unit. It needs the filter with mesh number
higher than that of the Filter(return side) 3.
If you use the pump which went through sufficient training driving, you
can avoid this.
The pressure resisting capacity shall be 30-50 kg/cm2 just as the pump
has.
Safety valve(or throttling valve) 5: This controls the flow rate which is sent into the
oil hydraulic power.
Heater (electric heater, steam heater, etc.) 6: This is used for heating up the
flushing oil to 70-80˚C
Reference : As above-mentioned, selection of pump and tank must be made
15
carefully. Then, there is a device which can be omitted and the flushing
device is simplified. If you fulfill the above-mentioned requirements, you
need at least the devices shown in the drawing at right.
(3) Drive the flushing pump and continue operation until the foreign matters are
completely extracted. Check the quantity of the foreign matters on the net of filter
in every 30-120 minutes during the operation.
Judgment of the end of flushing is given when you confirm that you can not see
any foreign matter on the net of 200 mesh after filtering for 30 minutes.
Note: Followings is the conditions under which you can not see any foreign
matters with naked eyes after filtering through the 200-mesh net.
Quantity of foreign
※ NAS 9 SAE, ASTM, 5
matters in 100cc
50 – 100 μ 720 430
More than
128 41
100 μ
※Though NAS Class 9 is preferable, about NAS class 10 is acceptable.
(4) It is necessary to give some shocks from out-side (hammering) during the
operation to quicken the fall of scales and other foreign matters. It is also effective
to heat up the oil temperature up to 60-70˚C by heater.
(5) To push in high-pressure nitrogen gas (clean and dry compressed air) into the
pipe from its discharge side, gives pulsatory motion to the oil current and takes
further effect in flushing.
(6) In case of branch pipe, one side is blanked and the other side is cleaned.
(7) The flushing oil to be used is preferably the flushing oil by the same maker who
16
makes the working fluid. Generally, the turbine oil with filling material and 1-2
degrees lower viscosity, is preferred to working oil.
5-4 Cleaning of the interior of oil tank (like the pipes, cleaning of the interior of oil tank is
extremely important)
Cleaning of the interior of oil tank is carried out as follows:
(1) Remove mill scales of steel plate on the inner wall of the tank (so-called “blank
sheet”), by grinder or wire brush.
But, this process can be omitted when mill scales are removed by sand blast
machine or pickling.
(2) Remove all the slags, spatters, and scales completely by file, chisel, grinder or wire
brush.
(3) If the hole of suction and return are made by gas cutter, clean the hole with grinder
or file.
If the difference between the diameter of the hole and the inside diameter of the
washer installed on the tank, is large, the resistance of oil flow also become large.
Therefore, the difference should be as small as possible. (less than 4 mm).
(4) Clean the inside and the out side of the suction pipe and return pipe within the tank.
The pipes are fitted to the tank with flange and they must be washed by chemicals.
(5) The foreign matters extracted by grinder must be removed by a bloom or sponge.
Do not use waste cloth because fibers often remain in the pipe.
(6) The inside of the oil tank is apt to rust in the long-time operation.
To prevent rusting, there are various kinds of coating material on sale. But, coating is
not recommendable because, unless pre-coating treatment and management of the
coating techniques are carried out perfectly, coating film may come off and may mixed
with the oil hydraulic circuit during the operation and may cause unexpected trouble. If
the rust-proof treatment is necessary phosphoric acid coating treatment is
17
recommended.
6. Fitting of pipe
6-1 Fitting of pipes
(1) At the time of fitting, confirm there is no foreign matter in the pipe. Especially
attention must be paid to whether the blank cap is off the position or is broken.
(2) Fit the pipes on the device with regular packings. Do not use O-ring which were
used in pressure-proof test or damaged packings. Be careful not to inflict damage
on the packings at the time of fitting.
(3) Confirm that the pipes are fitted smoothly.
(4) Bolts of flange or cap nuts of union join are fixed with the regular torque rod.
6-2 Anchoring
Pipes must be anchored with proper spaces between them in order to prevent vibration.
The construction and intervals of the support belts differ depending on mechanical
vibration in the circuit pressure pulsation, weight of the pipe and thickness of the pipe.
But you may follow the following standard.
(1) In the position 20 cm from the intermediate joint.

(2) Other than (1)
Pipe diameter
1/8B – 3/8B one in every 0.9 m
1/2B – 1B one in every 1.5 m
1 1/4B – 1 1/2B one in every 2 m
More than 2B one in every 3 m
7. Trial run
To carry out trial run, be cautious of the following points:
(1) Detection of foreign matters in strainer. Even if the piping work is carried out in
methods mentioned above, there is some foreign matter.
(2) Therefore, it is desirable that you use fine-mesh filter net of strainer and confirm
18
that the foreign matter is removed. And then change the net to the regular net and
carry out cleaning as occasion demands.
(3) Confirmation of oil leakage.
Soon after piping arrangement, oil leakage often occurs due to the failure of
inserting packing, incomplete fitting of packing or clamping of bolt or nut.
If you find any leakage, confirm the cause of leakage and repair it correctly.
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INSTRUCTIONS MANUAL
MAINTENANCE FOR THE GEAR
Supply lubricant (gear compound) on the gear teeth prior to running the winch.
GEA R
COM POUND
Working Oil and Lubrication Oil
Use Kind of oil Maintenance and checking

Working oil Hydraulic fluid or 1) Check the oil every voyage or
Antiwear type hydraulic every 3 months on color,
fluid ISO VG68~VG46 or impurity, etc.
equivalent.
Lubrication oil for JIS K 2219 “Gear oils” 2) Sample the oil every year, and
enclosed gears. Class 2 Industrial Use Submit it to inspection in the oil
ISO VG220 (or VG 320) maker
or equivalent.
3) After the inspection, consult with

INSTRUCTIONS MANUAL
the oil maker about the

necessity of the oil change.
Lubrication oil for JIS K 2220 “Lubricating Apply lubrication oil every month,
open gears. greases”, Gear as well as before and after using
compound Class 1, No2 the gears.
or equivalent.
Grease for JIS K 2220 “Lubricating Apply lubrication grease every

bearing greases”, for week, as well as before and after
and linkages. centralized greasing using the bearings and linkages.
system, Class 4, No. 2
or equivalent.
Referring to the above Table, if the specifications (brands) of oil/grease are

required to change, you are requested to consult with the oil maker or with our
engineers.
A. Checking of hydraulic fluid (An inspection method applied at site)
Sample the hydraulic fluid from the drainage of the main circuit and oil tank
Next, check and compare the sampled hydraulic fluid thus picked-up with the
new pre-sampled fluid.
·If the sampled hydraulic fluid is light-white/opaque and the transparency is
decreasing : This hydraulic fluid is being mixed with water.
·If the sampled hydraulic is brown and/or simulative smell is existed :
This hydraulic fluid is being deteriorated.
Be careful that if water-mixed/contaminated hydraulic fluid is used, it might

exert bad influences upon the oil-hydraulic system, etc.
Therefore, such water-mixed/contaminated hydraulic fluid must be changed
with fresh hydraulic fluid.

INSTRUCTIONS MANUAL
B. Changing of hydraulic fluid and lubrication oil.
a) Use the specified and same brand hydraulic fluid and lubrication oil at all times.
b) When any hydraulic fluid/lubrication oil is required to change, first, clean the
inside oil tank.
c) Be careful that harmful dust and foreign matters must not be entered into the
hydraulic fluid/lubrication oil.
When any hydraulic fluid is required to enter into the oil tank, filter the fluid by
using a filter provided with a 200-mesh or more fine filter element.
C. Others
Since the hydraulic fluid deteriorates at high-temperature. Be careful that the
oil temperature must be maintained at less than 65℃.

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INSTRUCTIONS MANUAL
Depending upon details of the trouble, we are ready to instruct you how to
overhaul, how to adjust, etc. , otherwise, we would like to dispatch our
engineer(s) to your facility.
Instruction for Replacing the Brake

Lining of Bolt-Nut Type
The brake lining used for this hydraulic deck machinery is secured to the brake
band by bolts and nuts.
The limit width that the brake lining is permitted to wear is as “Wear Limit” below.
If the brake lining is worn out to the position of the bolt head, it must be replaced.
If the brake drum is found to have a mark made by a contact with a bolt head,
immediately replace the lining.
Drum Chain Brake Brake Lining Wear Lining Thickness

Dia. Drum Thickness Limit for Exchange
Ø (mm) Dia. t(mm) S(mm) W(mm)
Ø (mm)
Chain Drum 73 1400 10 3 7
Hawser(Wire) 1200 8 2 6
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STAFFA RADIAL PISTON
HYDRAULIC MOTORS
70 SERIES OVERHAUL & MAINTENANCE MANUAL.

DATA SHEET : OHM-1001-2/07.01
Kawasaki Precision Machinery (UK) Ltd,

Ernesettle Lane, Ernesettle, Plymouth,
Devon, PL5 2SA, England
www.kpm-uk.co.uk
Tel: +44 (0) 1752 364394

Fax: +44 (0) 1752 364816
Copyright © Kawasaki Precision Machinery (UK) LTD.

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 Disassembly of ‘B’ type 7* series motor.
16 Assembly of ‘B’ type 7* series motor.
27 Disassembly of ‘C’ type 7* series motor
34 Assembly of ‘C’ type 7* series motor
44 Required tooling
47 Exploded diagram & component identification list for ‘B’

type motor.
49 Exploded diagram & component identification list for ‘C’

type motor.
STAFFA DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.
Introduction.
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:
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. 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. 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 PAGE 1 DATA SHEET

MOTOR OHM-1001-2/07.01
Model Code. (continued)

The following figure shows the model code for a STAFFA ‘C’ series motor.
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] FLUID TYPE

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

Blank = Standard (HMC)
HD = Heavy Duty (HMHDC).
[3] FRAME SIZE
[4] SHAFT TYPE
[5] HIGH DISPLACEMENT CODE
[6] LOW DISPLACEMENT CODE
[7] MAIN PORT CONNECTIONS
[8] DISPLACEMENT CONTROL PORTS

(AND SHUTTLE VALVE)
[9] TACHO / ENCODER DRIVE

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

PL** = Non-catalogued features, (**) = number assigned as required
Eg: Stainless steel shaft sleeves.
Alternative port connections.
Shaft variants.
Special mountings.

MOTOR OHM-1001-2/07.01
Torque Loading
BOLTS
THREAD SIZE S.H.C.S HEXAGON HEAD
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
M12 Nylon Nut N/A N/A 70 +/- 5 95 +/- 7
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
M18 Nyloc Nut N/A N/A 230 +/- 20 313 +/- 27
M20 390 +/- 20 530 +/- 27 300 +/- 20 408 +/- 27
M20 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

MOTOR OHM-1001-2/07.01
DOWTY BONDED WASHERS

Thread Size Imperial lbft Metric N.m
1/8" BSP M10 5 +/- 0.3 6.8 +/- 0.4
1/4" BSP M12 12 +/- 0.4 16 +/- 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

MOTOR OHM-1001-2/07.01
Restrictor Screw Identification
Restrictor Screw Identification Table
Restrictor Face Identification Marks Size Thread Size

1 x Circle .015" 7/16" UNF
2 x Circle .021" 7/16" UNF
2 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
Plain Face and 8 .8mm 7/16" UNF
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.

MOTOR OHM-1001-2/07.01
Trouble Shooting.
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

necessary parts with new ones.
4. Oldhams coupling broken. Inspect valve spool and replace

the required parts.
5. Con - rod restrictor blocked Replace all restrictors.
6. Excessive crankcase leakage. Inspect motor internals and replace

necessary parts with new.

MOTOR OHM-1001-2/07.01
Hydraulic Motor
Motor Shaft rotates 1. The inlet and outlet pipes have Change connections.
in reverse direction. been connected in reverse.
2. Valve spool has been incorrectly Align valve spool 'TDC' marks with
aligned with the crankshaft. crankshaft.
Fall in motor speed 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 Replace.

and bore.
6. Excessive wear between valve Replace.

and housing.
7. Excessive wear between Replace.

con - rod and piston.
Shaft seal leakage 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.

MOTOR OHM-1001-2/07.01
Hydraulic Motor
Oil Leakage 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

bolts.
Abnormal noise 1. Air in motor ports. Bleed air out.
("CHUFF" noise is
normal.) 2. Loose front cover. Correct it or replace.
3. Temperature too high. Reduce temperature

MOTOR OHM-1001-2/07.01
ASSEMBLY OF ‘B’ TYPE 7* SERIES MOTOR
No. PROCEDURE CAUTION
22. REFITTING DRAIN PLUGS.
Fit all gauge plugs and all case drain plugs with new
seal washers.

MOTOR OHM-1001-2/07.01
(7) DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.
1. PREPARATION.
Before removing the motor from the installation, clean All pipes that are
the surrounding area. Drain the motorcase by removing disconnected should be
the lower drain plug. covered to prevent damage
and contamination.
All piping that is disconnected should be marked to
assist with reassembly.
2. REMOVING THE FRONT COVER & SHAFT SEAL
Support the motor with the drive shaft pointing vertically Ensure that the two screws
upwards. Remove the cap screws bolting the front cover are tightened evenly as the
to the motorcase. Before removing the front cover ensure front cover is removed from
that the jacking threads are clean and not damaged. the motorcase.
Lubricate two of the front cover screws and use them in

the two threaded holes provided to jack the cover up.
Remove the shaft seal using a small flat chisel.
The front bearing cup can be removed using a
proprietary cup extractor
Fig 29.

MOTOR OHM-1001-2/07.01
DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.
3. REMOVAL OF SEAL CARRIER (if fitted).
If the front cover is fitted with a seal carrier, you should Some seal carriers are not
remove the cap screws first and then using your jacking fitted with jacking screw
screws, remove the seal carrier. threads. The carrier may be
removed by using a small
Once the cover and carrier are removed, the shaft seal iron drift on the inside of
and ‘O’ rings should be removed. the cover.
4. REMOVING THE CRANKSHAFT ASSEMBLY &

OLDHAMS COUPLING.
Remove the upper con rod retaining ring. Then Ensure that all slippers are
carefully lift the con rod slippers clear of the lower ring. clear of the lower retaining
(See fig 30 ). ring.
Fig 30.
Having disconnected the con rods from the lower

retaining ring, push the piston assemblies up into the
cylinder bores.

MOTOR OHM-1001-2/07.01
Next, using a hoist and lifting eye, lift the crankshaft out. Take care not to catch the
Once the crankshaft is clear of the motor, the lower rear bearing on the con rod
retaining ring and oldhams coupling can be removed. slippers or lower retaining
(See Fig 28). ring.
Fig 31.
5. REMOVAL OF DRUM & BEARINGS.

The bearing cones must be removed from the crankshaft If bearings show any signs
by means of a suitable extractor placed over the bearing of damage during removal,
rollers. (See fig 29). they must be renewed.
The crankshaft surface on

which the shaft seal lips run
must be kept clean and free
from damage.
Fig 32.
Care should be taken with

the small displacement
‘C’ rings should be removed from the end of the shaft. piston when removing the
It is advisable to remove the rear bearing first followed drum as it is spring loaded.
by the spacer plate and drum. Once the drum is clear of
the shaft the displacement pistons can then be removed

MOTOR OHM-1001-2/07.01
The front bearing can now be removed without the drum

dropping off.
6. REMOVAL OF PISTON ASSEMBLY.
Pull the con rod assemblys towards the center of the When removing the piston
motor until it clears the piston bore, then remove it from assemblies, mark each one
motorcase. to its respective bore.
Place on a suitable surface and release the circlip with

the appropriate circlip pliers.(See fig 33).
Turn the assembly over so that the con rod slipper is Care must be taken not to
resting on the surface. Rock the piston so that the half damage the bronze slipper
rings will fall clear of the piston. Once this is done the on the con rod.
con rod can be separated from the piston.
Both the piston seal rings can now be removed. If either of the rings are
damaged, they should be
replaced.
Fig 33.

MOTOR OHM-1001-2/07.01
The restrictor screws may be removed using a restrictor The restrictors are held with
removal tool. (See fig 34). loctite 542 and may be
difficult to remove without
the use of the restrictor
tool.
Fig 34.
7. VALVE SPOOL REMOVAL.
Turn the motor 90 degrees so that the motor is Due to the close clearances,
horizontal, do this by using a lifting eye and jamming may occur when
hoist. (See fig 35). the last portion of the valve
is still in the bore.
Remove the cap screws in the end cap. On some models
it is possible to screw a lifting eye into the end of the If this does occur, gently tap
valve spool to assist with removal. If the spool does not the valve back into the
come with a tapped hole in the end, it can be removed bore with a soft faced
carefully by hand. (See fig 35). hammer and try again.
Care should be taken when

handling steel rings, as they
can be very sharp.
Fig 35.
Remove the valve seal rings from the valve spool.

MOTOR OHM-1001-2/07.01
8. VALVE HOUSING & C-SPACER REMOVAL.
Turn the motor a further 90 deg (See fig 36 ). It is advisable to mark

Remove the cap screws which bolt the valve housing & the position of the valve
C-spacer to the motorcase. housing and ‘C’ Spacer
Remove the valve housing using the correct lifting relative to the motor case, to
bracket or a magnetic hoist. (See fig 36 ). assist with the rebuild of the
Then remove the C-spacer by hand. motor
Fig 36.
Once the C-spacer is lifted clear, the rear shim located

on the bearing cup can be removed.
9. REMOVAL OF CYLINDER END CAPS

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

MOTOR OHM-1001-2/07.01
10. REMOVAL OF SHUTTLE ASSEMBLIES

( ‘CS’ Models Only ).
F3” or FM3” Models
Remove shuttle stop plug & 1/4”BSP gauge plug (from

A port side). Then push out the shuttle roller, also from
the A port side.
Fig 38. Shuttle in valve housing.
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.

MOTOR OHM-1001-2/07.01
ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.
10. 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.
11. ASSEMBLE DRUM & BEARINGS TO SHAFT.
Bearings need to be heated to 120 degrees Celsius prior Check that all oil galleries
to fitting. It is recommended that the front spacer and are clean.
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.

MOTOR OHM-1001-2/07.01
Once the drum is located on the shaft, the spacer plates

(if fitted) should be located.
Check the cones are fully seated by tapping them with a Care should be taken not to
suitable steel drift. ( See fig 42.) damage the shaft seal.
POSITION CUTS
AT 180deg.TO
EACH OTHER.
Fig 42. 45deg.
The backing rings & C rings can now be fitted to the

shaft. The backing rings should be cut at 45 degrees
using a sharp knife and the C rings should be turned so
they are 180 degrees to each other ( See Dia B ).
Dia B.
12. STANDARD FRONT COVER ASSEMBLY.
Apply a small amount of ‘loctite’ 542 around the outer Take care to ensure that the
Dia of the shaft seal. Then press the seal into the front shaft seal is fully seated in
cover using the required shaft seal insertion tool. the cover.
( 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.

MOTOR OHM-1001-2/07.01
Fig 43.
13. FRONT COVER WITH SEAL CARRIER

ASSEMBLY. ( If Fitted.)
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).
Fig 44.
Once the ‘O’ Ring is fitted, the seal carrier can be

assembled to the front cover. Cross tighten the cap
screws to the correct torque settings. ( See Section 4
screw thread torque requirements.).
Press the front cover bearing cup into the front cover.
ensure that it is fully seated in the cover by using the
correct insertion tool.

MOTOR OHM-1001-2/07.01
14. CON ROD & PISTON ASSEMBLY.
Fit the restrictor into the con rod with a small amount When the restrictor is fitted
of loctite 542 on the thread. Tighten to the required to the con rod, check that
torque setting ( See section 5 Restrictor screw the hole in the restrictor is
identification ). 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 ).
Fig 45.
Cut and fit both seal rings on the piston groove. Ensure the nylon back up
(See fig 46, which shows how the seal rings should be ring is to the top of the
Cut.). piston.
90deg.
60deg.
Fig 46.

MOTOR OHM-1001-2/07.01
15. VALVE SPOOL SUB ASSEMBLY.
The steel rings need to be fitted. These have chamfers on Care should be taken when
both internal edges and come pre cut. Some models may fitting steel rings due to
plastic rings. ( See fig 47). sharp edges.
Fig 47.
16. REASSEMBLING PISTON ASSEMBLIES INTO

MOTOR CASING. valve housing or c spacer
mounting face
Before turning the motor, the bearing cup should be motorcase

fitted into the motorcase using the insertion tool. The rear bearing
cup should be knocked down into the bearing bore to crankshaft
correspond with the C spacer spigot depth. (See fig 48)

Fig 48
Now turn the motor to allow the pistons to be fitted.
Insert the piston assemblies into the bores from the X is equal to the length
inside of the motor housing. The seal rings should be of the C spacer spigot.
lightly held in its groove with a small amount of low .
melting point grease to prevent damage on entry. Take care not to damage
the piston seals.
Push each assembly outwards so the piston is fully
retained in the motorcase piston bore.

MOTOR OHM-1001-2/07.01
18. SHUTTLE SUB ASSEMBLIES

( ‘CS’ Models Only.)
F3, FM3 Valve Housing.
.
Fig 49.
Ensure that the shuttle freely

slides in the housing.
Slide shuttle roller in to its bore.

Fit plug with ‘O’ ring. ( See fig 49.)
F4, FM4 Valve End Cap
Fit one shuttle end plug complete with bonded washer

to the end cap.
Slide shuttle in to the bore. Then fit the other end plug
and bonded washer.
Fit the three pilot ‘O’ rings and valve bore ‘O’ ring to Ensure that the shuttle
is groove. freely slides in the housing.

MOTOR OHM-1001-2/07.01
17. REASSEMBLING CRANKSHAFT INTO MOTOR

CASING.
Place rear retaining ring into the motorcase, and hook

the ring under two of the con rods which are at the
crankshafts most eccentric position (TDC) (See fig 50).
Carefully lower the crankshaft into the motor.
Fig 50.
Once the shaft is in and over the rear retaining ring, the Take care not to damage
con rods can be lifted over the rear retaining ring. It the crankshaft or the bronze
will be necessary to carefully rotate the crankshaft to faces of the slipper frames.
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.
18. REASSEMBLING THE FRONT COVER TO THE

MOTORCASE.
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.

MOTOR OHM-1001-2/07.01
The front cover should then be placed over the shaft Note: All front covers are
onto the motorcase and aligned with the screw holes. are interference fits.
Gently tap the cover down squarely until all the front
cover cap screws can be started in their threads.
(See fig 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 Fig 52.
section seal should be fitted ( See fig 52).
Tighten the cap screws as below to the required torque.
1 4
1
4 8 7 6
6 9
9 8
Square section seal.
3 2
3 2
7 5
10 5

MOTOR OHM-1001-2/07.01
20. REPLACING REAR SHIM.
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.
Fig 53.
Fig 54.

MOTOR OHM-1001-2/07.01
ASSEMBLY FOR ‘C’ TYPE 7* SERIES MOTOR
21. ASSEMBLE THE VALVE HOUSING & C SPACER

TO MOTORCASE.
Fit the required port ‘O’ rings and boundary ‘O’ ring Take care not to damage
to the valve housing & C spacer. ‘O’ rings.
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

Fig 55. & valve housing are
correctly aligned to
the motorcase.
The C spacer can be placed onto the motorcase by hand.
Now the valve housing can be fitted onto the C spacer Once the C spacer & valve
using a suitable lifting bracket. The cap screws should housing are on the motor
be tightened evenly to the required torque setting case , do not twist them as
(See fig 56). this can cause damage to
‘O’ rings.
Fig 56.
Once the motor is built
complete, the free rolling
The oldhams coupling can be placed on the end of the torque should be measured.
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.

MOTOR OHM-1001-2/07.01
C200 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

MOTOR OHM-1001-2/07.01
Staffa
Spare parts listing - High torque low speed motors
C200,70
CODE DESCRIPTION QUANTITY PART No.
101 Motor Case 1 26040

102 Valve Housing
- "F3" with "CS" control ports 1 102-015
- "F3" with "C1" control ports 1 102-012
- "FM3" with "CS" control ports 1 102-014
- "SO3" with "C" or "X" control ports 1 102-016
- "SO3" with "C1" control ports 1 102-018
- "F4" with "C" or "X" control ports 1 102-003
- "F4" with "CS" control ports 1 75274
- "F4" with "C1" control ports 1 102-008
- "FM4" with "C" or "X" control ports 1 102-004
- "FM4" with "CS" control ports 1 102-006
- "SO4" with "C" or "X" control ports 1 102-001
103 Front Cover
- "Q" shafted motors only 1 103-006
- all other shafted motors 1 103-002
104 Valve End Cap
- "F3" & "FM3" ports 1 26128
- "SO3" ports 1 26128
- "F4" & "FM4" ports - not "CS" 1 24867
- "SO4" ports 1 24867
105 Cylinder Head 5 26042
109 Spacer
- "X" Displacement Control 1 109-002
- "C" Displacement Control 1 109-001
- "CS" Displacement Control 1 109-001
- "C1" Displacement Control 1 109-001
- "C2" Displacement Control 1 109-001
153 Shuttle End Cap ( "F4" & "FM4" , "CS"only ) 1 26250
201 Two Speed Crankshaft
30 Design :-
- "S" shaft 1 75257
- "P" shaft 1 75333
- "Z" shaft 1 75263
31 Design ( Low Noise ) :-
- "S" shaft 1 75873
- "P" shaft 1 75887
- "Z" shaft 1 75886
- "Q" shaft 1 76036
202 Piston 5 25032
203 Connecting Rod 5 25900
Standard seal kit 1 75091
Page 64
Staffa
Spare parts listing - High torque low speed motors
C200,70
CODE DESCRIPTION QUANTITY PART No.
204 Piston Retaining Half Ring 10 24961

205 Con Rod Retaining Ring 2 24409
206 Restrictor Screw 5 25973
208 Displacement Drum
- for "Q" shafts 1 27368
- for "P", "S" & "Z" shafts 1 26133
209 Large Displacement Piston
- 100 cubic inch Displacement 1 25625
210 Small Displacement Piston
30 Design :-
31 Design ( Low Noise ) :-
Page 65
COMPONENT IDENTIFICATION LIST FOR ‘C’ 7* SERIES MOTOR .
Item Qty. Description Bezeichnung ` Désignation Descrizione
Pos. Stückzahl
Rep. Qté
Pos. Qtà
101 1 Motorcase Motorgehäuse Carter moteur Corpo
102 1 Valve housing Ventilgehäuse Logement de valve Corpo valvola
103 1 Front cover Frontdeckel Couvercle avant Coperchio anteriore
104 1 Valve end cap Ventilenddeckel Obturateur d'extrémité de valve Cappello estremità valvola
105 5 Cylinder head Zylinderkopf Culasse Testa cilindro
201 1 Crankshaft Kurbelwelle Vilebrequin Albero a gomiti
202 5 Piston Kolben Piston Pistone
203 5 Connecting rod Pleuel Bielle Biella
204 10 Piston retaining half ring Kolben-Halbring Demirondelle de retenue du piston Semianello di ritegno pistone
205 2 Con rod retaining ring Pleuel-Haltering Bague de retenue de la bielle Anello di ritegno biella
206 5 Restrictor screw Drosselstopfen Vis de limitation Vite di restrizione
209 1 Large displacement piston Kolben, groBe Schluckvolume Piston de grand cylindree Pistone a lunga corsa
210 1 Small displacement piston Kolben, kleines Schluckvolumen Piston de petite cylindree Pistone a corta corsa
212 1 Spring Feder Ressort Corta
(displacement piston) (kolben) (piston de cylindree) (molla)
214 Front Plate Frontplatte Plaque avant Flangia
301 1 Valve spool Drehschieber Tiroir Cursore
303 1 Oldham coupling Oldham Kupplung Accouplement flottant Giunto di Oldham
305 1 Shim kit Unterlegscheibensatz Jeu de cales Kit di spessoramento
(steel) (Stahl) (acier) (acciaio)
401 1 Rear bearing Hinteres Wellenlager Roulement arrière Cuscinetto posteriore
402 1 Front bearing Vorderes Wellenlager Roulement avant Cuscinetto anteriore
404 5* Piston seal ring Kolben-Dichtring Bague du joint de piston Fascia elastica pistone
405 12* Valve seal ring Ventil-Dichtring Bague du joint de valve Anello di tenuta valvola
408 5 Circlip Seegerring Circlips Anello elastico
(piston internal) (Kolben innen) (piston, interne) (interno pistone)
410 1* O-ring O-ring Joint torique O-ring
(front cover) (Frontdeckel) (couvercle avant (coperchio anteriore)
(valve end cap) (Ventilenddeckel) (obturateur d'extrémité de valve) (cappello estremità valvola)
(cylinder end cap) (Zylinderenddeckel) (chapeau d'extrémité du vérin) (cappello estremità cilindro)
(internal ports) (innere Kanäle) (orifices internes) (aperture interne)
417 * Shaft seal Wellendichtring Joint d’arbre Guarnizione d’albero
418 5 S.H.C.S Zylinderschraube Vis fraisées à six pans creux Brugola
(Valve assembly to motor) (Ventilanbau an Motor) (pour lemontage de la valve (complessivo valvola al motore)
sur le moteur)
419 10 S.H.C.S. Zylinderschraube Vis fraisées à six pans creux Brugola
(front cover) (Frontdeckel (couvercle avant) (coperchio anteriore)
420 45 S.H.C.S Zylinderschraube Vis fraisées à six pans creux Brugola
(cylinder head cap) (Zylinderenddeckel) (chapeau d'extrémité du vérin) (cappello testa cilindro
422 # S.H.C.S Zylinderschraube Vis fraisées à six pans creux Brugola
(valve end cap) (Ventilenddeckel) (obturateur d'extrémité de valve) (cappello estremità valvola
426 2* Bonded seal, drain Dichtring, Ablaß Rondelle d'étanchéité Guarnizione a labbro, spurgo
de vidange
435 2 Drain plug Ablaßschraube Bouchon de vidange Tappo di spurgo
452 Small piston seal ring O-ring, kleiner kolben Bague du joint du petit piston Anello di tenuta per pistone a picolo
diametro
453 1 Large piston seal ring O-ring, groBer kolben Bague du joint du petit piston Anello di tenuta per pistone a largo
diametr
(external ports) (Systemanschlüsse) (orifices externes) (aperture esterne)
476 5* Back-up ring Stützring Bague anti-extrusion Anello antiestrusione
(cylinder end cap) (Zylinderenddeckel) (chapeau d'extrémité du vérin) (cappello testa cilindro)
479 2 Steel plug Stahlstopfen Bouchon acier Tappo di acciaio
(valve housing) (Ventilgehäuse) (chambre de valve) (corpo valvola)
482 1* O-ring O-ring Joint torique O-ring (cornice sede valvola)
(valve housing surround) (Ventilgehäuse-Einfassung (enveloppe du logement de valve) (cornice sede valvola)
483 5* Piston seal backing ring Kolben-Stützring Bague de renforcement Anello di supporto fascia elastica
du joint de piston pistone
484 1 Key Paßfeder Clavette Chiavetta
485 1 Washer, long taper shaft Unterlegscheibe, Rondelle, arbre conique long Rondella, albero rastremato lungo
langer kegeliger Schaft
486 1 Nut, taper shaft Mutter, kegeliger Schaft Ecrou, arbre conique Dado, albero rastremato
788 1 Split pin, long taper shaft Splint, langer Goupille fendue, Coppiglia, albero rastremato
kegeliger Schaft arbre conique long lung
PAGE 50. DATA SHEET OHM-1001-2/07.01

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1. NEVER SET THE SLIPPING POINT OF A SPRING LOADED BAND BRAKE
TO 80% OF ROPE MBL. THAT WILL CAUSE A FINAL BRAKE HOLDING
LOAD EQUAL TO 95%~100% OF ROPE MBL
2. EACH WINCH BRAKE IS TO BE TESTED INDIVIDUALLY AND TESTS ARE
TO BE CARRIED OUT PRIOR TO THE VESSEL’S DELIVERY AND EVERY
YEAR. IN ADDITIION, INDIVIDUAL WINCHES ARE TO BE TESTED AFTER
COMPLETION OF ANY MODIFICATION OR REPAIR INVOLVING WINCH
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ALWAYS TIGHTEN THE BRAKE UNTIL THE MIDDLE OF INDICATOR RING
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WHEN THE MIDDLE OF INDICATOR RING COINCIDES WITH THE INDICATOR
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SAFETY PRECAUTIONS

MUST fully understand how to use the product.

cautions in this manual.

1. Warning and Cautions for operation

2. Warning and Cautions Related to Maintenance

CHAPTER 2. SPECIFICATION & DRAWING

CHAPTER 4. INSTRUCTION FOR MAINTENANCE AND CHECKING

CHAPTER 5. TROUBLE SHOOTING LIST

CHAPTER 6. DETAIL DESCRIPTION OF MAIN PARTS

CHAPTER 7. ASSEMBLY DETAIL

COPYRIGHT FLUTEK, LTD

COPYRIGHT FLUTEK, LTD

STORAGE INSTRUCTIONS FOR

COPYRIGHT FLUTEK, LTD

5. Long-term equipment storage strategy

room with above temperature condition.

- Equipment Storage must be kept the above conditions.

COPYRIGHT FLUTEK, LTD

SPECIFICATIONS & DRAWING

COPYRIGHT FLUTEK, LTD

Alkyd resin zinc chromate and iron

Alkyd resin enamel

S1140 / 41 / 42 / 43 / 44 / 45 / 46 / 47 / 50 / 51 / 67 / 68 / 69 / 70 / 5120 / 5121

Alkyd resin zinc chromate and iron

Alkyd resin enamel

Paint maker Refer to Yard paint Spec.

Detail method Manufacturer's standard

7. HYDRAULIC FLUID AND LUBRICANTS

JIS K 2220 Gear compound For one lubrication

JIS K 2219 Gear oil Class 2, For one lubrication

JIS K 2220 Grease Concentric For the first lubricating

* Contamination:NAS 1638 Class 9 (ISO 4406-/18/15 equivalent)

* Proper viscosity to use : 25cSt ~ 200 cSt

LIST OF SPARE PART AND TOOLS

HULL NO. : S1138/39/40/41/42/43/44/45/46/47

MESSER'S. FLUTEK, LTD

LIFTING GUIDANCE – Cable lifter unit

- The cable lifter is delivered in one unit

- Remember always to put safety first.

LIFTING GUIDANCE – Mooring winch (One drum)

LIFTING GUIDANCE – Mooring winch (Two drum)

Publication October 1961

MARINE MACHINERY DIVISION

Limited to the necessary parts for field assembly

Bending Working order may seem to be simple. But, if correct

2-2 Identification before start of piping.

completely covered by vinyl sheet.

3-1 Pipe cutting

Union and butt welding pipe joints (elbow and cheese)

3-2 Joint welding

Table for standard welding rod:

Notations and Brands

3-3 Piping molding

3-4 Fitting of accessories

4. Pressure proof test

5. Cleaning of the interior of pipe

5-2 Chemical cleaning (acid washing, chemical flushing, etc.)

Filter 2: To be installed on the discharge

Attached Table : Chemical Cleaning Methods and Liquids

Caustic soda 5- Soaking or circul-

Injection by pressurized water, pressurized hot water and high-pressure steam.

5-3 Oil flushing

(2) connect with flushing pump.

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