Kawasaki Staffa Radial Hydraulic Motors

Kawasaki
Hydraulic Products
srAFFA RADiAL P ~ STON

IHYlOlRAIU U C MOTORS
"
70 SERIES OVERHAUL & MA INTENANCE MA NUAL.

DATA SHEET: OHM-1001 -2/07.01
,\,
Kawasaki Preci sion Machinery (U K) Ltd,

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

Fax: +44 (0) 1752 3648 16
Copyright © Kawasaki Preci sion 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 Troubl e Shooting
10 Di sassembly of ' 8 ' type 7* series motor.
16 Assembly of '8' type T seri es motor.
27 Disassembly of 'C' type Y series motor
34 Assembly of'C' type 7* series motor
44 Required tooling
47 Exploded diagram & component identifi cation li st for '8'

type motor.
49 Exploded di agram & component identification list for 'C '

type motor.
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STAFFA DATA SHEET
Hydraulic Products
MOTOR OHM- tOOI -2/07.01
Overhaul & Maintenance manual.
Introduction.
When maintaining a Staffa Radial piston hydraulic motor, the recommend ations and
speci fi cations detailed throughout this manual must be follow ed at a ll times.
Servicing of Staffa motors should only be carried out by a authori zed repairer.
The cl ea nliness of the workspace and components is of prime importance.
Take note of the followin g headers points:
1. P r ep a r a tion.
I . This manual can be used for the disassembly and assembly of most 'B ' or ' C' series
motor. Before commencing with the disassembly of the motor, make a note of the model
code on the motor ( See section 2 Model code) and become famili ar with its specifications.
2. Prepare the tools required for the specified motor before begining commencing disassembly.
A Service tool table is provided ( See section Required tooling).
3. The assembly torques specified must be strictly adhered to. Use correctly calibra ted torque
wrench.
2. Disassembly.
1. Ensure that your surrounding work area is clean and free from sources of contamin ation .
2. Spread rubber sheets, cloth, etc., on the work bench to prevent parts from being
da maged.
3. If a part seems difficult to remove, stop and examine the component and identify the
problem. If impact forc e is required, only use a pl astic 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 use of other th an original "STAFF A" parts will reduce the
life of a motor.
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. '0' ring . All ' 0' rings should be replaced once it has been in service.
}
STAFFA PAGE 1 DATA SHEET Hydraulic Products
MOTOR OHM-I 001 -2107.0 1
28/07/2001
Overhaul & Maintenance manua l.
Model Code.
Th e fo llowing fig ure shows the model cod e for a STAFFA 'B' series motor.
Bas ic 'B ' Series Ordering Code
F1 1 - HM *B - 060 - S3 - FM3 - Tx - * - PL **
[1] [2] [3] [4] [5] [6] [7] [8]
[1] FLUID TYP E
Blank = Mineral Oil
F3 = Phosphate ester (HFD fluid)
F11 = Water based flu ids
[2] MODEL TYPE

Blank = Standard (HMB)
HD = Hea vy Duty (HMHD B)
[3] FRAME SIZE
[4] SHAFT TYPE
[5] MAIN PORT CONN ECTIONS
[6] TACHO I ENCODER DRIVE

Blank = None
T = Staffa original tacho drive
Tx = Custom er specific encoder drive
[7] DESIGN SERIES NUMB ER
[8] SPECIAL FEATURES

= =
PL" Non-ca talogu ed features, (") number assigned as required
Eg: Stainless steel shaft slee ves .
Altern ativ e port connection s.
Shaft vari ants.
Special mountings.
STAFFA PAGE 2 DATA SHEET

Hydraulic Products
MOTOR OHM- tOOI-2/07.01
28/0712001
Overh aul & Maintenance manual.
Model Code. (continued)

The following figure shows til e model code for a STAFFA .C' series motor.
Bas ic 'C' Series Orderin g Code
F11 - HM*C - 200 - S3 - 188 - 90 - FM4 - CS - TJ( - 30 - PL**

[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11 ]
[1] FLU ID TYPE
Blank = Petroliu l11 oil
F3 = Phosph ate es ter (HFD fluid)
F11 = Water based flu ids
[2] MODEL TYPE

Blank = Standard (HMC)
HD = Heavy Duty (HMHDC).
,
)
[3] FRAM E SIZE
[4] SHAFT TYP E
[5] HIGH DISPLACEMENT COD E
[6] L OW DISPLACEM ENT COD E
[7] MAIN PORT CO NN ECTION S
[8] DISPLACEMENT CO NTROL PORTS

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

T = Sta ffa original tach a drive
Tx = Cu stom er spe cific encoder
[10] DESIGN SERIES NUMB ER
j [11] SPECIAL FEATURES

PL" = Non-ca talogued fea tu res , (") = number assigned as required
Eg: Stainless steel shaft sleeves .
Altern ative port conn ection s.
Shaft variants.
Special mountings.

Hydraulic Products
MOTOR OHM-I 00 1-2/07.01
Overh aul & Maintenance manua l.
Torq ue Loadi ng
._.-._-_. _-_.--_._--------- - _._- - - ------ - ---_._- -- -~--~ .--- - _.._ -----

BOLTS ,
THR EAD SIZE S.H.C. S HEXAG ON HEAD
Im pe ri a l T hr e ad lm peria ll bft M e tric N .m Itn pe ri a llbft Me tric N.m
1/4 " UN F 1 UN C 13 +/- 2 18 +/- 3 9 +/- 2 12 +/- 3

5/ 16"UN F 1 UN C 27 +/- 5 37 +/- 7 20 +/- 3 27 +/- 4
3/S "UN F / UN C 45 +/- 5 61 +/- 7 35 +/- 5 48 +/- 7
1/2"UN F 1 UN C 110 +/- 10 150 +/-1 4 85 +/- 5 11 6+/- 7
9/16"UN F 1 UNC 150 +/-1 5 204 +/- 21 123 +/- 15 167 +/-21
5/S "UNF / UN C 215+/-20 292 +/- 27 170 +/- 15 231 +/- 21
3/4"UN F / UN C 355 +/- 20 483 +/- 27 290 +/- 20 394 +/- 27
Me tric T hrea d
M6 10 +/- 2 14 +/- 3 9 +/- 2 12 +/- 3

MS 27 +/- 5 36 +/- 7 21 +/- 3 29 +/- 4
M 10 50 +/- 5 68 +/- 7 40 +/- 5 54 +/- 7
M12 85 +/- 5 11 6 +/- 7 70 +/- 5 95 +/- 7
M12 Nylon Nul N/A N/A 70 +/- 5 95 +/- 7
M 12 Loc k/Ny lo n N/A N/A 28 +/- 5 38 +/- 7
M 14 140 +/- 15 190 +/- 2 1 11 6 +/- 15 158 +/- 21
M 16 200 +/- 20 272 +/- 27 180 +/-1 5 245 +/- 21
M1S 280 +/- 20 381 +/- 27 230 +/- 20 313 +/- 27
M1S Nyloc Nul N/A N/A 230 +/- 20 313 +/- 27
M20 390 +/- 20 530 +/- 27 300 +/- 20 408 +/- 27
M20 Nyloc Nul N/A N/A 300 +/- 20 408 +/- 27 ...I
M24 510 +/- 20 694 +/- 27 430 +/- 20 585 +/- 27
Values are based on followin g materials:

Socket head cap screws 170,000lblin (120kglmm) UTS - Grades 12.9
Hexagon head screws ll 4,000lb/in (80kg/mm) UTS - Grades 8.8
STAFFA
MOTOR
PAGE 4 DATA SHEET
OHM -1001- 2107. 0 I
!:S
Hydraulic Products
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28/0712001
- - - - - - - ~-- -- .. - ..,- . _.---,. -- - -- - - ----- - -- --

DOWTY BO NDED WAS HERS
Thr ea d S ize Imp e ri a llb ft Me tric N ,m
1/8" SS P M10 5 +/- 0.3 6.8 +/- 0.4

1/4" SS P M1 2 12 +/- 0.4 16 +/- 0.5
3/8" SS P M1 6 23 +/- 1.0 31 +/-1 .4
1/2" SS P M20 42 +/- 2.0 57 +/- 2.7
3/4" SS P 58 +/- 3.0 79 +/- 4.0
1" SS P 92 +/- 4.0 125 +/- 5.4
3/4" UN F 30 +/- 1.0 4 1 +/- 1.4

MOTOR OHM - IOOI-2/0 7.01
28/07/2001
R estrictOl' Screw Ide nti ficatio n
Res trictor Screw Id entification T able
Rcs trictor Fa c e Id e ntific a tion M arks S ize T hr ea d S i z e
1 x Circl e .015" 711 6" UN F
2 x Circl e .02 1" 7/1 6" UN F
2 x Circl e and X .028" 711 6" UN F
Pl ai n Fa c e & X .0 40" 7/1 6 " UNF
Plain Fa ce & Groov e at Nose End .01 9" 7 /1 6 " UN F
Pl ain Fac e .5mm Bmm x 1. 25p

j
Pl a in Fa c e and 8 .8 mm 7 /1 6" UN F
R estrictor Torqu e Requirements

Maximum restrictor torgue 11 Nm ( 81bs/ft )
All restrictors must be sea led around their thread using thread locking fluid.
(Suitable fluid, would be 'Ioctite' 542.)
Care must be taken to ensure th e restrictor hol e remains clear.
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Hydraulic Products
MOTOR OHM· IOOl · 2/07.01
28/07/2001
Overhaul & Maintenance mamlH I.
Troub le Shooting.
lf any prob lems occur during the running of your motor, before starting any fault di agnosis,
check the fo llowing:
(a) Oi l level.
(b) Pressure, flows and temperatures.
(c) Noise and vibration in the system.
(d) Air and oi l fi lters.
If a component is found damaged or not to the correct specific ation, the component and
surrounding area shou ld be clea ned and the component replaced. Whi lst cleaning look out for
loose bits of paint as this is a common problem and care should be taken to prevent the off
breaks of paint ii·om entering the system.
Great care should be taken when handli ng components, to ensure they do not get damaged,
especially moving pal1s, i.e. Pi stons, bearings or rotary valve-s etc.
F atl lt Diagn osis.
Hydraulic Motor
Fault Poss ible Ca uses Remedy
Mo tor w ill not run 1 . Overl oad Re leas e load .
2. Re li ef val ve in th e circ uit is not Se t valve to the cor rec t va lu e.
set correc tl y.
3. Se iz ur e of movin g part s. Insp ect motor intern ally and replac e

nec ess a ry part s w ith new on es .
4 . Oldh ams coup l ing br oken. Inspect valve spoo l an d repl ace
th e required part s.
5 . Con · ro d restri ctor block e d Re pla ce a ll restri cto rs .
6 . Exce ssi ve c rank c ase lea kag e. Inspect moto r in tern als a nd repl ace
necessa ry parts with neVI.
STAFFA PAG E 7 DATA SHEET

Hydraulic Products
MOTOR OH M· 100 t·2107.0 1
28/07/200 1
Overhaul & M aintenance manual.
Hydraulic Motor
Fault Poss ible Causes Remedy
M otor S haft rot a tes 1. The inle t and outl et pip es have Ch ange conn ec tions .
in re ver se d i r ec tion . bee n co nn ec ted in reve rs e .
2 . Valve spool has bee n incorrectly A lig n va lve spool 'TOC' marks with
a li gned with th e cranksh art . crank sha ft .
Fa ll In motor s p ee d 1. Drop in flow from pump. Chec k d isc harge flow from pump.
2. Te mperatu re too high ca us ing Re duce oil temp eratur e.
e xc e ssi ve pump lea ka ge .
3. Va lve s worn or brok en. Re pl ac e .
4. Pi st on sea l worn o r brok en. Re pl ac e.
5. Exc e ssi ve wea r betwee n pi ston Re pl ac e.
and bore.
6 . Exc ess ive wear between va lve Re pl ac e .
a nd housin g.
7. Exc e ssive wea r betwee n Re pl ace.
con - rod and pis ton.
S h aft se a l l ea k ag e 1. Shaft seal worn or da mage d. Re pl ace sea l.
2. High case pres s ure . Red uce pres sur e .
3. S hall dam aged . Re pl ace or fit spee di e sleeve.
4. Side lo ads Reduce til e sid e lo ad.
5. Inco rrect sh imming (front or rear). Ch eck th e bearin g & re sh im motor.

Hydraulic Products
MOTOR OHM- IOO l-2107.01
28/0 7/200 1
Overhaul & M aintenance manu al.
Hydraulic Motor
Fa ult Poss ible Ca uses Remedv
Oil Lea ka ge 1. '0' Ring dam age d. Replace .
2. '0' Ring missin g Re pl ace and in ve sti ga te cause .
3. Dam age to sea lin g fac es. Dis a ss embl e a nd corr ect.
4 . Bolls loos e . Re - tight en to correc t torqu e .
5. Brok en bolts. Re place a ll bolts and re-torqu e
bolts.
Ab normal noi se 1. A ir in motor ports. Bl ee d air out.
(,'CHUFF" noi se is
norm a l.) 2. Loose front co ver. Corr ect it or repl ace .
3. Tem p era ture too high. Re du ce tem perature
)
Hydraulic Products
MOTOR OHM-IOO 1-2/07.01
28107/2001
(6) DISASSEMBLY OF ' B' TYPE 7'" SERIES MOTOR.
No. PROCEDURE CAUTION
1. PREPARATION.
Before removing the motor from the installation, clean All pipes th at are
the surrounding area . Dra in the motercase by removing disconnected should be
the lower drain plug. covered over to
prevent from damage and
All piping that is disconnected should be marked to contamin3tion.
ass ist with reassembly.
,
2. REMOVING THE FRONT COVER & SHAFT SEAL )
SUpp0l1 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 l\vo of the front cover screws and use them in

the two threaded holes provided to jack the cover up.
Remove the shaft sea l using a small flat chisel.
The ti'ont bearing cup can be removed using a propri etary
cup extractor
Fig 1.

Hydraulic Products
MOTOR OHM-IOOI-2/07.01
DISASSEMBL Y OF 'B' TYPE 7" SERIES MOTOR.
3. REMOVAL OF SEAL CARRIER (if fitted).
If the front cover is fitted with a sea l carrier, you should Some sea l carri ers are not
rcmove the cap screws first and then using your jacking fi tted with jacking scrcw
screws, remove the sea l carri er. 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 '0' ri ngs should be removed. the cover.
\ 4. REMOVING THE CRANKSHAFT ASSEMBLY &

OLDHAMS COUPLING.
First remove the upper can rod retaining ring. Then Ensure that all slippers are
carefully li ft the can rod slippers clear of the lower ring. Clear of the lower retaining
( See fi g 3 ). rm g.
Fig 3.
Having disconnected the can rods from the lower

retaining ring, push the piston assemblies up into the
cylinder borcs
)
Hydraulic Products
MOTOR OHM-IOOl-2/07.01
Overhau l & Maintenance manual.
DISASSEMBLY OF 'B' TYPE 7'" SERIES MOTOR.
Next lift the crankshaft out, using a crane and lifting eye. Takc care not to catch the
Once the crankshaft is clear of the motor, the lower Rear bearing on the can rod
retaining ring, the oldhams coupling can be removed. slippers or lower retaining
(S ee Fig 4). nng.
Fig 4.
s. REMOVAL OF BEARINGS.
The bearing cones must be removed from the crankshaft If bearings show any signs
by means of a suitabl e extractor pl aced over the bearing of damage during removal,
Rollers. (S ee fi g 5). they must be renewed.
The crankshaft surface on

which the shaft seal lips run
must be kept clean and fiee
from damage .
Fig 5.
The front bearing cup can bc 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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Hydraulic Products
MOTOR OHM-tOO t-2/07.01
6. REMOVAL OF PISTON ASSEMBLY.

Pull the can rod assembly towards the center orth e When removing the pistoll
motor until it clea rs the piston bore, then remove it from asse mbli es, mark each one
the molorcase. to its respective bore.
Place on a suitable surface and release the eirclip with the

eirclip pliers.( See fi g 6).
Turn the asse mbly over so that the can rod slipper is Care must be taken not to
resting on the surface. Rock the pi ston so that the half damage thc bronze slipper
Rings will fall clear of the piston. Once this is done the Oil the can rod.
) can rod can be seperated from the piston.
Both the piston sea l rings can now be removed. If either of the rings are
damaged, they should be
Repl aced.
Fig 6.
The restrictors are held with

loctite 542 and may be
The restri ctor screws may be removed using a restrictor difficult to remove without
removal tool. ( See fi g 7 ). the use of the restrictor
Tool.
Fig 7.
STAFFA PAGE J3 DATA SHEET

Hydraulic Products
MOTOR OHM- 1001-2107.01
7. VALVE SPOOL REMOVAL.

As a result of close
Turn the motor 90 degrees so th at the motor is cl ea rances, jam.mi ng may
hori zonta l, clo this by using a lifting eye and a crane. occur when the last portion
(See fig 8). of the valve is still in the
bore.
Remove the cap screws in the end cap, then screw a If this does occur, gently tap
A lift ing eye into the end of the valve spool. Use the the valve back into the
Li fting eye to assist with lifting the spool out of the bore with a soft faced
Bore. ( See fi g 8). hammer ancl try again .
)
Fig 8.
Remove the valve seal rings from the valve spool.

j
8. VALVE HOUSING REMOVAL.
Remove the cap screws which bolt the valve housing to

the motorcase.
Remove the va lve housi ng using the con ect lifting
bracket (See fig 9).

MOTOR OHM-IOOI-2107.01
Overhau l & Maintenance manu al
DISASSEMBLY OF ' B' TYPE 7* SERIES MOTOR.
PROCEDURE CAUTION
No.
Fig 9.
Once the valve housing is lifted clear, the rear shim

located on the bearing cup can be removed. I fth e shim
is to be replaced the old can be disposed of, if not the
shim should be kept in a cl ean and safe pl ace
Next the rear bearing can be removed by pressing or B400 are fitted with an
tapping with an iron drift towards the center of the outer bearing housing
1110tOr. which has to be removed
before the bearing cup can
be taken out of the motor.
9. REMOVAL OF CYLINDER END CAPS.

To remove the 'Cylinder end caps, the end cap Care should be taken not
screws must be removed, then the end cap may be to damage the pi ston bores.
,, withdrawn by using a steel drift to tap the end cap
from inside the cylinder bore. (See fi g 10).
Fig 10.

Hydraulic Products
MOTOR Ol-lM-IOOI-2107 .01
Overhaul & Maintenance manu al
ASSEMBLY OF 'B' TYPE 7'" SERIES MOTOR.
10. PREPARATION BEFORE REASSE MBLY.
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 BEARING TO CRA NKSHAFT.

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Heat the rear bearing to 120deg Celsius ( 250 deg
Farenhieght ).
Then place the bearing squ arely onto the appropri ate Care should be taken not to
shaft. Check that the cone is fully seated by tapping it damage th e shaft sea l
with a suitable steel drift. (S ee fi g II). contact zone.
Fig II.
Once the rear bearing has cooled down, turn the shaft
over and carry out the same procedure for the front
bearing.
)
MOTOR OHM-IOO 1-2107.01
Overhaul & Maintenance manti a I
12. STANDARD FRONT COVER ASSEMBLY.
Apply a small amount of 'loctite ' 542 around outer dia Take care to ensure that the
Of the cover seal. Then press the sea l into the front cover shaft seal is fully seated in
tlsing the required shaft seal insertion tool.(S ee fi g 12) the cover.
Remove any excess loctite from around the seal or

Housing.
The recesses between the lips of the seal should be fill ed

with a suitable high melting grease.
Fig 12.
13. FRONT COVER WITH SEAL CARRIER

ASSEMBLY.
Insta ll the shaft seal. To do this carry out the same

procedures as for a standard front cover.
Once the shaft sea l is fitted the carrier can be fitted.

Fit '0' Ring to either sea l carrier or to the extern al
dia of the bearing cup.(See fi g l3)
Fig 13.

Hydraulic Products
MOTOR OHM·IOOI-2/07.0 I
Overh aul & Maintenauce manual
ASSEMBLY OF ' B' T YPE 7'" SERIES MOTOR.
Once the '0' ring is fitted, the sea l carrier can be

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

I
Fit the restrictor into the con rod with a smear ofloctit e When the restrictor is fitted
542 on the thread. Ti ghten to the required torque to the con rod, check that
Setting ( See Sec 5 Restrictor screw identification). the hole in the restrictor is
still cl ear.
Thinly coat the ball of the con rod with a small amount
Of molybdenum grease (to aid initiall'llnning ). Fit
Circlip loosely over the neck of the con rod and
Partially in sert the ball of the con rod into the piston
Seat. Insert the two half rings and pu sh them into the
Recess until the circlip can be fitled into its groove.
(See iig 14).
Fig 14.
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Hydraulic Products
MOTOR OHM-IOO 1-2/07 .0 1
ASSEMBLY OF 'B' TYPE 7" SERIES MOTOR.
No. PROCEDURE CAUTIO N
Cut and fit both seal rings on to the piston groove. Ensure the nylon back up
(See fi g IS, which shows how the seal ring should ring is to the top of the
Be cut.). Piston.
Fig IS.
15. VALVE SPOOL sun ASSEMBLY.

Scarf cut the rings at 45dcg to each other (See fi g l6) On some models steel rings
And assemble to valve spool (See fig 17). M ay be fitted. These have
Chamfers on both internal
Edges and come pre cut.
4 5 clog. <
Fig 16.
,
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Take care to assemble nylon rings with the chamfered
edge face out.
Fig 17.
) DATA SHEET
STAFFA PAGE 19 Hydraulic Products
MOTOR OHM·1001 · 2107.01
ASSEMBLY OF 'B ' TYPE 7" SERIES MOTOR.
16. REASSEMBLING PISTON ASSEMBLIES INTO

MOTOR CASING.
Before turning the motor, the bearing cup should be

fitted into the motorcase using the insel1ion tool. The
cup should be Imockec1 clown into the bearing bore to
correspond with the valve housing spigot.(S ee Dia A).
N ow hlnl the motor to allow the piston to be fitted. DiaA.

Insert the piston asse mblies into the bores from the
inside of the motor housing. The sea l rings should be Take care not to damage ,
lightly held in its groove with a sma ll amount of low piston seal. .
\
melting point grease entry.
Push each asse mbly outwards so the piston is fully

retained in the motorcase piston bores.
RE ASSEMBLING CRANKSHAFT INTO MOTOR

CASING.
Place rear retaining ring into the motor case, and hook Take care not to damage
the ring under two of the con rods which are at the the crankshaft or the bronze
crankshafts most eccentric position (TDC) (S ee fi g 18). slipper frames on the con
Carefu lly lower the crankshaft into the motor. rods.
.,
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Fi g 18.

Overh aul & Maintenance manual
ASSEMBLY OF 'B' TYPE 7" SERIES MOTOR.
On some models (I-IM "'B I 00) the crankshaft Take care not to damage
needs to be tipped s lightly to a llow the rear beming to the bea ring surfaces of the
go under the rear retaining ring (See fi g 19). con rod.
Fig 19.
Once the shart is in and over the rear retaining rUlg, the
con rods can be lifted over the rear retaining ring. It
will be necessmy to carefully rotate the crankshaft, by
doing this you will bc able to check that all the con rod
slippers rest against the th row.
Next the top retaining ring can be fitted over the can
rods. Both can rod retaining rings should be able to
move freel around the con rods.
18. REASSEMBLING THE FRONT COVER TO THE

)
) MOTORCASE.
Fit '0' ring to the spigot of the front cover.
Before fittin g 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 s leeve or, when the
spline diameter is the same as the seal di ameter, use
50mlll masking tape coated with hi gh m elting point
Grease.
,
)
MOTOR OHM-1001-2/07.0 1
Overh au l & Maintenance manu al
The front cover shou ld then be placed over the shaft onto
the motorcase and aligned with the screw holes . Gently
tap the cover down squarely until all the front cover cap
screws can be started in their tlu"eads.(See fi g 20).
,•
Fig 20.
Evenly screw the cover down and tighten the screws to

the recommended torque.
19. REFITTING CYLINDER HEADS.

Fig 21.
If the cylinder heads have been removed, a new square
section sea l should be fitted (S ee fi g 2 1).
Ti ghten the cap screws as below to the required torque.
;
-'
G
Square section sea l.
!-IMB06010801l 00 !-1MB 125/ 150/200/27 0/325

Hydraulic Products
MOTOR OHM-IOOI-2/07.0 1
Overhaul & Maintenance mal1l181
ASSEMBLY OF 'B' TYPE 7"" SERIES MOTOR.
20. REPLACING REAR SHIM.

(This procedure do es not apply for B400, see page 24)
Turn motor so valve housing face is facing up.

Obtain a rolling torque figure with no load acting
on the bearing. Then tap the bearing cup down until the
rolling torque fi gure increases by 2 to 3 ft lbs.
Zero your depth gauge on the va lve housing (See fi g 22)
Next measure the depth of the bearing cup in four places

to ensure that the CLIp is square to the motorcase.
(See fi g 23).
Now add O. l mm to that depth, thi s will

give YOll the required shim pack, which can be fitled
to the motor.i.e
Bearing cup depth = 0.55m111
0.55ml11 + 0.1 mm = 0.65mm shim pack
F ig 22.
)
Fig 23.
If rear shim is not to be replaced, reuse the old.

Hydraulic Products
MOTOR OHM-1001-2/07.0 I
ASSEMBLY OF 'B' T YPE 7" SERIES MOTOR.
11 REPLACING REAR SHIM FOR B4 00.
Install inner bearing housing & outer bearing ring (A) in

correct position in th e motorcase.
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
rift.
Fi g 24.
~ r
Set depth gauge (D) to zero using a 25mm Datum block Fig 25.
(E) ( Part No 440-106-1 77) as illustatcd in Fig 25.
Place measurement bridge(C) ( Part No 440-106-1 76)

on the valve housing mounting face, as shown and Ensure that the bearing is
measure depth to bearing face.(See fi g 26). down evenly, by measuring
Add O.lmm for (pre load) to determine shim thickness the height of the bearing
required. in four pl aces.
Fi g 26.

Hydraulic Products
MOTOR OHM- l 00 1-2/07.01
Overhaul & Maintenance manu al
ASSEMBLY OF 'B' TYPE 7'" SERIES MOTOR
21. ASSEMBLE THE VAL VE H OUSING TO TH E

MOTOR CASE.
Fit the required port '0' rings and boundary '0' ring
to the va lve housing.
1fS03 or S04 valve housing then fit ent ry port '0' rings.
Fit ' 0 ' ring retai ners into motorcase ports if required
( See fi g 27) .
.'
Fig 27.
Now the valve housing can be fitted onto the motorcase Ensure the valve hous ing is
using a suitable li fting bracket. The cap screws shou ld put on in the correct
be tightened evenly to the required torque setting a lignment to the motorcase.
(S ee fi g 28).
Once the valve housing is
On the motorcase, do not
Twist it as it ca n damage the
'0' rings.
Fig 28.
The oldhams coupling can be placed on the end of the

Shaft, the valve spool can be carefull y lowered into the
Housing using a lifting eye. You must ensure that the
Va lve spool TOC lines up with the shaft TOe & engages
With the oldhams coupling. The end cap can now be
Fitted, tighten cap screws to correct torque.
)
~ ________ ~ __________ ~ ________ ~Kavvasaki

MOTOR OHM-1001-2/07.01
Overh aul & Maintenance manll al
ASSEMBLY OF ' B' TYPE 7·:' SERIES MOTOR
22. REFITTING DRAIN PLUGS.
Fit all gauge plugs and all case drain plugs w ith new
Seal was hers.
1-----~-----..,._----___4!:5
STAFFA
MOTOR
PAGE 26 DATA SHEET
OHM- IOO 1-2107.01
Hydraulic Products
)
Overhaul & Maiutenance manua l
(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 motercase 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 vertica lly Ensure that the two screws
upwards. Remove the cap screws bolting the front cover are tightened evenly as th e
to th e motorcase. Before removing the front cover ensure front cover is removed fro m
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 j ack the cover up.
Remove the shaft sea l using a small fl at ch isel.
The front bea ring cup can be removed using a proprietary
cup extractor
Fig 29.

Hydraulic Products
MOTOR OHM- IOOI-2/07.01
DISASSEMBLY OF 'C' TYPE 7* SERIES MOTOR.
3. REMOVAL OF SEAL CARRIER (if fitted).
lfthe front cover is fi tted with a seal carrier, you shou ld Some sea l carriers are no!
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 '0' rings should be removed. the cover.
4. REMOVING THE CRANKSHAFT ASSEMBLY &

OLDHAM S COUPLING.
Remove the upper can rod retaining ring. Then Ensure that all slippers are
+carefully lift the can rod slippers clear ofthe lower rin g. clear of the lower retaining
( See fi g 30 ). ring.
Fig 30.
Ha ving discOlll1ected the can rods from thc lower

retaining ring, push the piston assemblies up into the
c linder bores .

MOTOR OHM- IDOl -2107 .0 1
Overhnui & Maintenance manual
DISASSEMBLY OF 'C' TYPE 7* SERIES MOTOR.
Next lift the crankshaft out, usin g a crane and lifting eye. Take care not to catch the
Once the crankshaft is clear of the motor, the lower Rear bearing on the can rod
retaining ring and oldhams couplin g can be removed. slippers or lower retaining
(S ee Fig 28). ring.
Fi g 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 pl aced over the bearing of damage during rellloval,
Rollers. (See fi g 29). they must be renewe(l.
The crankshaft surfa ce on

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

the small displ acement
'C' Rings should be removed from the end of the shaft. piston when removing the
It is advi sable to remove the rear bearing first follow ed by drum as it is spring loaded.
the spacer pl ate and chum. Once the drum is clear of the
shaft the dis lacement )istons can then be removed
\
f
MOTOR OHM-IOO 1-2/07.0 1
O verhaul & Maintenance manual
DISASSEMBLY OF 'C' TYPE 7'" SERIES MOTOR.
The front bearing can now be removed without the drum

dropping off.
6. REMOVAL OF PISTON ASSEMBLY.
Pull the can rod assemblys towards the center or 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 ap propriate circlip pliers.(See fig 33 ).
Turn the assembly over so that the can rod slipper is Care must be taken not to
resting on the surface. Rock the piston so th at the half damage the bronze slipper
rings will fa ll clear of the piston. Once this is done the on th e can rod .
can rod can be separated from the piston.
Both the piston seal rings can now be removed. If either of the ri ngs are
damaged, they should be
repl aced.
,
!
Fi cr 33.
)
MOTOR OHM - IOO l -2/07.01
DlSASSEMBL Y OF 'C' TYPE 7" SERIES MOTOR.
The res trictor screws may be removed using a restrictor The restrictors arc held with
Removal tool. (See fi g 34). loctite 542 and may be
difficult to remove without
the use of the restrictor
tool.
Fig 34.
7. VALVE SPOOL REMOVAL.
Tum the motor 90 degrees so that the motor is As a result of close

horizontal, do this by using a lift ing eye and clearances, jamming may
Crane. (See fi g 35). occur when the last pOl1ion
of the valve is still in the
Remove the cap screws in the end cap. On some models bore.
you can screw a lift ing eye into the end of the valve If this does occu r, gently tap
spool to assist with removal. If the spool does not come the valve back into the
w ith a tapped hole in the end, it can be removed bore with a soft faced
carefu lly by hand. ( See fi g 35). hammer and try again.
Care should be taken whcn

handling steel rings, as they
can be very sharp.
Fig 35.
Remove the valve seal rings from the va lve spool.
)
Hydraulic Products
Overh aul & Maintenance manu al.
DISASSEMBLY OF 'C' TYPE 7°" SERIES MOTOR.
8. VALVE HOUSING & C-SPACER REMOVAL.
Turn the motor a further 90 deg (S ee fi g 36 ). It may be advisable to mark

Remove the cap screws which bolt the valve housin g & the position of the valve
C-spacer to the motorcase. housing and 'c' Spacer to
Remove the valve housing usin g the conect lifting the motorcase, to assist with
Bracket or a mag netic crane. (See fi g 36 ). the rebuild of the motor
Then remove the C-spacer by hand.
Fig 36.
Once th e C-spacer is lifted clear, the rear shim located

on the bearing cup can be removed. If the shim is to be
repl aced the old can be disposed of, if not the shim
should bc kept in a cl ean and safe place.
9. REMOVAL OF CYLINDE R END CAPS

To remove the cylinder end caps, firstly the end cap Care should be taken not ,
to damage the piston bores. J
screws must be removed, then the end cap may be
withdrawn by llsing a small bronze drift to tap the end
cap from inside the cylinder bore. (See fi g 37).
Fig 37.
;
STAFFA PAGE 32 DATASIIEET
Hydraulic Products
DISASSEMBLY OF 'c' TYPE 7" SERIES MOTOR.
10. REMOVAL OF SHUTTLE ASSEMBLYS

( 'CS' Mod els Only).
F3 " 0 1' FM3 " Mod els
Remove shuttle stop plug & 1/4"BSP gauge plug (from

A port side). Then push out the shuttle roller, also fro m
the A port side.
'.
,l
Fig 38. Shuttle in Va lve Housing.
F4" 01' FM4" Motors
Shuttle assembly is located in valve end cap. Remove

Both shu ttle stop plugs and bonded washers and push
out shu ttle from end cap. (See fi g 39.)
J ._Jr-_'
FiO' 39. Shuttle in End Cap.
r-----s-T-A-F-F-A----~----P-A-G-E-<-3-3--~---D-A-T-A-S-H-E-<E-<T--~I~
MOTOR OHM-100 1-2107.01
ASSEMBLY OF 'C' TYPE 7" SERIES MOTOR.
10. PREPARATION BEFORE REASSEMBLY.
On reassembly of all components, ensure th at they are

clean and free of contamination.
Certain components may require a small sm ear of

hydraulic oil to assist with reassembly.
11. ASSEMBLE DRUM & BEARINGS TO SHAFT.

.
Bearings need to be heatcd to 120 degrees Celsius prior Check that all oil gall eries ,I
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 fi g 40). Both the large & small di splacement
pistons should be fitt ed into the shaft.
Fig 40.
;
The displ acement pistons need to be pushed right down
into their bores, so the drum can be fitted. This is done
by using a G cl amp to hold them in place. (See fi g 4 1).
Fig 4 1.
.
.>
H~draulic Products
MOTOR OHM-1001-2/07.01
Ovcrhaul & Maintenance manual.
ASSEMBLY OF 'C' TYPE 7'" SERIES MOTOR.
Once the drum is located on the shaft, the spacer pl ates

should be pl aced on (if fitted).
Check the cones are fully seated by tapping them with a Care should be taken not to
suitable steel drift. ( See fi g 42. ) damage the shaft sea l.
Fi g 42.
The backing rings & C rings can now be fitted to the

Shaft. The backing rings should be cut at 45 degrees
using a sharp knife and the C rings should be turned so
they are 180 degrees to each other ( See Di a B ). Di a B.
12. STANDARD F'RONT COVER ASSEMBLY.
App ly a small amount of ' Ioctite ' 542 around the ouler Take care to ensure that the
Di n of the shaft seal. Then press the sea l into the front shaft sea l is fully seated in
Cover using the required shaft sea l insertion tool. the cover.
( See fi g 43.).
Remove any excess loctile from around the sea l 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 fu lly seated in the cover by using the
correct insertion tool.
)
STAFFA PAGE 3S DATA SHEET
Hydraulic Products
MOTOR OHM·1001· 2/07.0 1
Fig 43.
13. FRON T COVER WITH SEAL CARRIER

ASSEMBLY. (If F itted.)
Firstly install the sha ft seal. To do this cany out the

same procedures as for a standard front cover.
Once the shaft sea l is fi tted the carrier can be fitt ed.
Fit '0 ' Ring to either the seal carrier or to the external
Dia of the bearing cup. ( See fi g 44).
Fig44 .
Once the '0' 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.

Hydraulic Products
MOTOR Ol-IM- 100t-2/07.01
No. PROCEDURE CAUTIO N
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. T ighten to the required to the con rod, check that
torque setting ( See section 5 Restrietor serew the hole in the restrictor is
identification ). still cl ear.
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 neek of the eon 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 eirclip can be fitted into its groove.
( See fi g 45 ).
Fig 45.
Cut and fit both seal rings on the piston groove. Ensure the nylon back up
(See fi g 46, which shows how the sea l rings should be ring is to th e top of the
Cut.). piston.
Fig 46.
)
/
Hydraulic Products
Overhaul & Maintenance manu al.
15. VALVE SPOOL SUB ASSEMBLY.
The steel rings need to be fitte d. These have chamfers on Care should be taken when
both internal edges and come pre cut. Some models may fitting steel rings, as they
plastic rings. ( See fi g 47). are very sharp.
,
-'
Fig47.
16. REASSEMBLING PISTON ASSEMBLIES INTO

MOTOR CASING.
Fig48.
Before turning the motor, the bearing cup should be
Fitted into the motorcase using the insertion tool. The X is equal to the length
cup should be Imocked down into the bearing bore to of the C spacer spigot.
correspond with the C spacer spigot depth. (See fi g 48)
Now turn the motor to all ow the pistons to be fitte d.

Insert the piston assemblies into the bores from the
Inside of the motor housing. The seal rings should be
Lightly held in its groove with a small amount of low
Melting point grease to prevent damage on cnhy .
Push each assembl y outwards so the piston is fully

Retained in the l1l0torcase piston bore.
Take care not to damage
the pi ston seals.
\
I

MOTOR OHM-100I-2/07.01
18. SHUTTLE SUB ASSEMBLIES

( 'CS' Mod els Only.)
F3, FM3 Valve Housin g.
Fi g 49.
) Ensure that the shuttle freely

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

Fit plug with '0' ring. ( See fi g 49.)
F4, FM4 Valve End Cap
Fit one shuttle end plug compl ete with bonded washer
to the end cap. Ensure that the shuttle
Slide shuttle in to the bore. Then fit the other end plug freely slides in th e housing.
and bonded washer.
Fit the three pilot '0' rings and valve bore '0' ring to
IS groove.
~----S-T-AF-<F-<A----'-----P-A-G-E--39----r---D-AT-A--SH-E-<E-'T---11 ~
MOTOR OHM-100I-2!07.01 Hydraulic Products
ASSEMBLY OF 'c' TYPE 7':' SERIES MOTOR.
No. PROCED URE CAUTION
17. REASSEMBLING CRANKSHAFT INTO MOTOR

CAS ING.
Place rear retaining rin g into the motorcase, and hook

The ring under two of the con rods which are at the
Crankshafts most eccentric position (TDC) (See fi g 50).
Caref11lly lower the crankshaft into the motor.
.
,
Fi g 50.
Once the shaft is in and over the rear retaining ring, the Take care not to damage
con rods can be li fted over the rear retaining ring. It the crankshaft or the bronze
will be necessmy to carefully rotate the crankshaft, by faces of the slipper frames.
doing tbis you will be able to check that all the con rod
slippers rest against the throw.
Next the top retaining ring can be fi tted 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 '0' ring to the spigot of the front cover.
Before fi tting the front cover, the splines on the shaft

must be covered to prevent them from getting damaged,
to do thi s you can use either a steel sleeve or, when the
splin e di ameter is the same as the seal di ameter, use
50mm masking tape coated with high melting point
Grease.
.
"

Hydraulic Products
MOTOR OHM- 100l-2/07.0 1
The front cover shou ld then be pl aced over the shaft onto Note : A ll front covers are
the motorcase and aligned with the screw holes . Gently are interference tits,
tap the cover down squarely until all the front cover cap this is part of the
screws can be started in their threads. (See fi g 51). deign.
Fig 5 1.
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 Fi g 52.

section seal should be fitted ( See fi g 52).
Tighten thc cap screws as below to the required torque.
Square section seal.
\
/
Hydraulic Products
MOTOR OHM-100I-2/07.01
ASSEMBLY OF 'e' TYPE 7'" SERIES MOTOR.
20. REPLACING REAR SliM.
Turn motor over. So valve hOllsing mounting face is rfrear shim is not to be
Facing up. Firstly obtain a rolling torque figure with no replaced, rellse the old.
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 NI11).
Zero depth gauge on the C spacer spigot

(See fi g 53).
Next measure the depth of the bearing cup in four places

to ensure that the cup is square to the motorcase.
(See fi g 54).
Now add 0.1111111 to that depth, this will give you the
Required shim pack, which can be fitted to the motor
I. e.
Bcaring cup depth ~ 0.55mm
0.55mm + O.lmm ~ 0.65mm shim pack.
Fig 53.
Fig 54.

Hydraulic Products
MOTOR OHM-l 00 1-2/07.0 1
ASSEMBLY FOR 'C' TYPE 7'" SERIES MOTOR
21. ASSEMBLE THE VALVE HOUSING & C SPACER

TO MOTOR CASE.
Fit the required port '0' rings and boundary ' 0 ' ring Take care not to damage
to the valve housing & C spacer. '0' rings.
IfS03 or S04 valve hou sing then fit cntTY port '0' rings. If C spacer is a Ctop type
motor, their is an additional
Fit '0' ring retainers into motorcase & C spacer ports if sma ll '0' ri ng. Ensure this
required ( See fi g 55). Js fitted.
".
Fig 55.
Ensure that the C spacer

The C spacer can be placed onto the molorcase by hand. & valve housing arc put on
Now the valve housing can be fitted onto the C spacer in the correct ali gnment to
using a suitable lifting bracket. The cap screws shou ld the motorcase.
be tightened evenly to the required torque setting
(See fi g 56). Once the C spacer & valve
housing are on the motor
case, do not twist them as
this can cause damage to
'0' rings.
Fig 56.
The oldhams coupling can be placed on the end of the

shaft, the valve spool can be carefu lly lowered In to the
housing with the aid of a ring compressor sleeve, this Once the motor is bui lt
help with the steel rings. You must ens ure that the valve comp lete, the free rolling
spool TOC lines up with the shafts TOC & engages with torque should be measured.
the oldhams coupling. The end cap can now be fitted,
make sure the cap screws are done up to the correct
tor ue settin o .
,
\
Hydraulic Products
MOTOR OHM- 1001-2/07.0 1
Overhaul & M aintenance manual.
REOUIRED TOOLING.
NAME SHAPE MODEL SIZE

TYPE
B030toBl00 (PtNoOI 4801) 112" UNF
B1 25 to B3 25 (PtNo 01 4802) 3/4" UNF
Lift in g Eye C1 25 to C3 25 (Pt No 01 4802) 3/4" UNF
B400 3/4" UNF
R estrictor screw A ll Sizes. (Pt No 014740)

R emoval tool.
)
Valve housin g F2 - FM2 (Pt No 015055)

lifting bracket. S03 - F3 . FM3 (Pt No 015056)
S04 - F4· FM4 (Pt No 015057)
BO I 0/B030/B080lC030lC045 Pt No 014690
Shaft seal Bl00 - C080 Pt No 014692
Insertion tool. B1 25 - 200 1 C125 - 200 Pt No 014693
B270 - 325 1 C270 - 325 Pt No 014694
HDB 125 - 200 Pt No 014694
B400 PtNo 014694
B400 Brid ge
For rear shim. .. B400
(Pt No 440-106- 176) .
. ~- -.

Hydraulic Products
MOTOR OHM-1001-2/07.01
26/07/2001
REOUIRED TOOLING (cont).

TYPE
25 Illm DatullI
Gauge. 1- ' r i B400
(PI No 440- 106-176).
Circlip Pli ers

-
~C
-''...
~,.
-
j All Sizes L = 2 10
Torqu e wrench F - . i '. ~ All Sizes 0.25N / 20 - 300 NI11
f~ - = '~
112",5/32",7/32",
Hexagon Socket All Sizes 3/8", AlF.
(112" Sq. Drive). L = 60
"~~t-X
6ml11 & j Ol11tll AF.
\
) 5/32",7/32",3/8",
I~"
Hexagon I: "4"'" All Si zes 112", AF.
wrench Key. L = 160
I
STAFFA
MOTOR
PAGE 45 DATA SHEET
OHM-IOOI-2/07.01
1!!:5
Hydraulic Products
26/07/2001
Overhaul & Maintella nce 1118IlUal.
REOUIRED TOOLING (cont).

TYPE
Depth All Sizes.

Mirom ete r
Bea rin g Most models, see

Extractor . manual.
Ring F4, FM4 Di a. 10 lmm

Compressor F3 , FM3 Dia.76111111
Dial Clock All Sizes. 0.00 - 5.00 mm

gauge

Hydraulic Products
26/0 7/2001
Overh aul & MaiutenHnce manu aL
B200 7'" SERIES EXPLODED DIAGRAM

MOTOR OHM- I 00 1-2/07 .01
COMPONE NT IDENTIFJCA TION LIST FOR ' B' 7" SERIES MOTOR .
It em Qly. Dcscd pti oll Dczcirhnun g Dcs igll:ltioll Dcscl"izion c
Pos. Stilcbahl
Rep. Qle
Pas. Qt"
10 1 I fvlotorcase !"v!otorg!,;!l:iusc C:l rler 1110tClif COI'IJO
102 Valve hOllsin g Ventil gehallse Logemen t de va lve C.orpo valvo la
103 From cover Frontdcc kel Couve rcl~ avant Coperchio antcriorc
104 Valve end ca O Vcnli lc nddcckel QbIU[ill!i:I![ d'!i:x ' rCnli ' ~ de valve Caope llo eslremita va lvo la
105 5 C.vlinder h~!l cl Zyl indc rkonf Cu! nssc TesI" cilindro
20 1 Crnnkshaft Kuroelwl< llc Vilebregllin Albero a gamil;
202 5 Piston Kolben Piston P i ~ t one
203 5 Connecting rod Plctlc! Siel le Biella
204 10 P i~ lon retainin g half rin g Kolb c n~Halb ril1 g DCIJljrQIl(kll!,;; ~Ic rC I ~ lm£ ell! piston Scmi anell o <Ii [i tcgno pi s tOIl~
205 2 COl] rod rel[linin!! ring PI ~l1 e l- H a ll c ring Baglllt ~I ~ relcnue de la bie1!e Ancll o eli r i t ~t!:l1o bi ella
206 5 B.~w i ctQ r s:~ r~w Oros~e l slQQ fen Vis d!:l lil]lilation Vile eli rcst rizjQne
)01 Valvc snool Orchschicber Tiroir Cllrsore
303 Oldham coupl ing Oldhnm KUPQlull!! AccauQlcmcnt flo lt(1l1l Ginnta di Oldham
305 Shim kit UnlerIe {!seh ci be nsal7. JCLI d ~ ~l! l cs Kit dj sgessor!! Plento
(s teel} (Stahl) (a c i ~r) (acciaig)
401 Rea r bearinl! Hinteres Wellenlae.er RQuielncnt <llT jerc Cuscinclto Qosteriore
' "2 Front bea ring Vorderes Wellenlng!:l[ ROl1 l~me n t nV3n l C.ll~!;;j netto an1eriorc
Piston sen I rillg Gague dll joint d ~ pistOl]
4U5
5'
12* Valve seal rin g
Ko lben-Di!;; ht rill[!
Vcnt il -Oi cht rin g BagHc ell! joint de valve
Fass::ia elast ica pi stone
Anell o di tCHula va lvola '-
408 5 Circl ip Seege lTing Circlips Ancllo elastica
(piston imcllml) (Kolbcn inne n) (niston in te11le) Cint emo Ililitonc}
410 I' O-ri ng O-ri ng loint torique Q-ring
(Il'ont cover) (Frontdeckell (cQll v!:lrs:: l!:: !lvan! (!;;operchio anteriore)
413 I' a -ring a -ring Joillt toriqHe O-ring
(valve end can) (Venti lendc!eckel) (oblllratCl1l' d'extremite de valve} (ea pgcllo eslrc miln valvo!al
414 5' O-ring O-ring Joint toriqllc O-ring
(cvlinder end can) (Zxlind crencldeckcl) (clJagcau d'extrcmitc du verin) (cappe llo est rem it;i. cilindro)
415 5* O-ring D-ring loint toriqlle D-ring
(i ntcma l jlOrts) (illncre Kan ti le) (orificcs internes) (aperture intcrnc)
41 7 • Shaft seal Wellendiclit ring Joint c!'arbre OJlllrni zione ~1 '~ ll2 cro
4 18 5 SH C.S Zyl imlcrschrallbe Vi s fraisees asix pails crcux Bl1Igola
(Valve assembly to motor) (Venti lanbilll an Motor) (pour lellloJltage de la valve (compl ess ivo va lvola al molorc)
slIr Ie mot clIr}
419 10 SHC.S. Zylinderschraub e Vis fmisces it six pans creux Dl1Igola
(front cover) {Frontdcckcl (coll v~rc l c avant) (copcrchio ant ~[ i orc)
420 45 SHC.S Zylinderschl'Rllbc Vis fraisces a six pans crellX Bntgola
(~v l illd c r head !;;B P) (Zvlindcrcnddeckel) (c h ane a~1 d'e;s trcmite du verin} (cappello t C~ ! B ~ i lill d ro
422 ff S. H.C. S Zylind crschril.ube Vis frai secs a six pails crCllX Brllgola
(valvc end cap) (Ventilcnddeckel) (obturatellr d'extrcmilt: de valve} (canpeHn eslrcmitfl valvola
.' .... ~ 2' Donded sea l, drain Dichtring, Abla13 Rondel lc d'e-Iancheil!! Guamizione a labbro, sPl\l'b
,
de vi d:ull'e
435 2 Dmin ohm Ahl af3sc hrallhe BOllchon dc vidfltl gc Tappo di spurgo
474 2' O-ring Q· ring Joint loriqlle O-ring

(extcnm l ports) (SyslemanschWsse) (ori fi ces extern es) (npertllrc e~ l e fl l c}
476 5' Bac k-up ring Sti.itzring Bague anti -cxtnlsioll Ancllo ant icstJ'HSiollc
(c~ lind c r CI}d ~jlp) (ZXI ind e re !J ~ ld e!< kc l l (chapeau d'cxtrcmite cit! verin) (ca ppe llo testa cilindro)
479 2 Steel plug SI<lhlstopfcn Bouchon (Icier Tappo di acciaio
(va lve hOllsing) (Vent il o ~ h1i l1sc ) (cham!Jr!:l dc va lve) (!<Q[Qo valvQln)
482 1* O-ring a-ri ng Join! lorique O-ri ng (comicc sede va lvo la)
(valve hOllsin l! SlltTOllnd) (Vent il gehtiu sc-Ein fassllll g (e nvel o Q~ e dl! l og~lIlc n! de \ 'll !VC) (cornice s ed ~ vjl lvola)
483 5* Piston sca l backing ring Kolben-Sttltzring Bague de rcn forcclllent Anello <Ii SllppOItO fascia elastica
dl! joint t1g piston nis-tOile
4R4 Kev PaR[!<der Cl aveue Chiavet ta
485 Washer. long Inne[ shaft Unterle l?schcibe Rondell e nrbre coniQlIc Ion I! ROll della. albel'Q rastrclllnto Inn go
langeI' kegcJi ger Schafl

486 Nut, taper shnfl Muttcr, kegcligcr Scha ft ECI'Oll, arbrc con iquc Daclo, albero rastremato
788 Split pin , long taper shaft Splint, langeI' Goupille fendue, Coppiglia, albcro rastl'cmato
kegeliger Schaft arbrc coni que long lung
PAGE 48. DATA SHEET OHM-IOO l-2/07.0 1

C200 7'" SERIES EXPLODED DIAGRAM
Viev.-.; on Arro w "A"
\
j

MOTOR OHM-IOOI-2f07.01
CU1Vl1'UNJ!:NT W J!:N TlFICATlUN LIST FOR 'C' 7" SERIES M OT OR.
It em QIY· Desc riptio n Be7.cichllung Dcs iglllltioll ]) cscr iziollC

>. Stiicbnhl
.. p. Qte
Pos. Ola
10 1 I Motorcasc MOIOrccha llsc Cart~[ molctll" Con'"!o
10' I Valve hOIl:i:ing Vcnti lgelliiusc LogC1ll CIH de va l ve Coq~o valvola
10J I Front cover Frontdcckcl COllverclc avant COl1crchio anleriorc
104 I Vnlve end cap Vcntil cllddcckcl ObtuTntc\lr d'cxlrcmitc (Ie va lve Cnppcilo c:i:trs;:m ita valvola
105 5 Cylinder head Zvlinderkopf Cula:!:sc Tesla cilin dro
201 I Cra nkshaft Kurbelwc lle Vi lebrcq uin Alb!;;ro a gamil ;
202 5 Pi:i:!on Kolben Pi ston Pi:!:tQ llc
203 \ CQllnectiJ]!; rod Pl ctle} Sid le Bie!la
204 10 Pi ston retaining half rin g Kolbcll·Ha lbring DcmirQndcllc de rCI\;!1us du piston SC lllianello eli ri lcg no pistone
205 2 Con rod rctn iping ring Plcuel -Haltcri n!! Bal!ue de retenue e1!;; In bi elle Anc ll o di rile!!110 bieJla
' Q6 2 Rcst riclor screw Dross!;;lslOn fen Vis de Iillljl1!li on Vile di reslrizione
209 la rge di ~ pl a!';!t: m ell t piston /::;olhcn g[Q[!C Sc hl uck vo l ll lll ~ Piston dc era nd cy lindree Pistonc a Imlea corsa
210 Small displaccment pi st01l Kolbcn ~I£j n cs Schlllct volllll1 C'Il Pi stol' de petite c ~ li ndr~e Pi stone a cgrfa corsa
212 Spring Fedcr R CSSOl1 Corta
(disglaccID!t:ll t piston) (kolben) (nistQI] de c;:llindrs;e) (IllQll a}
214 Front Plate Frontulalle Plaguc avant El angi a
301 Va lve snoo l Drehschi!t:hcf Tiro ir Cur:;orc
303 Oldham CQII12ling: OldhaJ]l Kunn illn g Accoupl cment fl ottOllt Giunto di Oldha m
305 Shim kit Unl e[ieeschcibi,; nsatz Jeu de ca les Kit Qi sgcssora mento
(sl!;;!;;1} (Stahl) (acier) {accia io}
Rear bearillg Hintcrcs Wcnclllal! cr Roul ement arriers< C:uscin eltQ posterjQre ",
Front bearine: Vordcrcs Well enl agc r Roulcment ,wanl C!l ~c in e tlo a 11 1~rj orc i
404 5' Piston sea l rine Ko lben-Dichll; ng Ba gll!il: C!U joint de piston Fascia elasti ca pistone
405 12' Valve sea l ring Vcntil·Di chlring B a g ~l e dl1 joint tie v a lv~ AIl!:lIo di tenula valvo la
408 5 Circl ip Seegcrring Circl ips Anello elastico
(pjSIQI1 i Jlt~mllll (Kolben jnnt!n) (j2iston int erne) (i nt crno pislone)
410 I' O-ring a-ring Joint tori que O-ring
(rronl cover) (Frontdcckel) (collverclc avant (eoperchio antcri ore)
413 I' O-ring O-ring Joinl torique O-ring
(valve end can) (Ventilcnddeckel) (obtumtcur d' ex l rcl]1 i t~ de valv!;:) ( ~ap n e llo c~ t remit a valYQla)
414 5' O-ring O-ring Joint toriquc O-rin g
(c:tlind er end cap) (Zvl ind er!:llddeckel} (chapeau d'!;;xtremite dn verin) (!;;fJ Ppell o eSlrcr}] ita cilin dro)
415 5' a-ring O-ri ng Joint torique O-ring
(i ll l ~ana l p o rl~ ) (innerc Kani'i lc) (orifi ces internes} (aperture intcl1lc)
41 7
, Shaft seal Wellendi ehlring loint d '~ rbre Gunmizione d'nlbero
418 5 S. H.C.S Zylindcrschrallbe Vis frili sces it six pnns CfellX O1'ugola
(Vnlve asse mb ly to mOlar) (Vent ilanbau an Motor) (pour ICl110ntage de la valve (complessivo va lvola al motore)
snr Ic !ll QI~lIr}
419 10 SHC.S. Zy lindersch raube Vis frai sccs ft six pans crellx Bmgola
(front cover) (Frontdcckel (couv c [!;i l ~ avant) (collerchio nn l ~[ i ore)
420 45 S.RC.S Zylinderschraube Vis frai sces II six pans erellx Dntgola
(c:ili nder head cap:) (Zvlindercnddcckel) (chn Qcnll d'extrcm itc du vcrin) (cnppell0 testa cilindro
422 # S.H.C.S Zylindcrschraube Vis frai sces a six pans crellx Drugola 1
(valve end cnn) (Venlilenddcckcl) (obturnteur d'extn!mitc de ,'alvs;) (can12d lo es t rclll il ~ valvo la .'
, -" 2* Bonded sea l, drain Diehtring, Ablaf3 Rondelle c!'etanchcitc Gu arnizionc a labbro, spurgo
de vidnngl;:
4J5 2 Drain I}lu g Abla l3s!;;hp\\l bc Souchon de vidan"c Tnppo di spu rgo
452 Small piston seal ring O-ring, kleiner kolben Bnguc elu joint dn pet it piston Anello di tenlltn pcr pistone a pieolo
diamctro
453 Large piston sea l ring a-ring, groBcr ko lben Bague dll joint dll pctit piston Anello di tcnuta per pistone a largo
di nplct r
474 2' O-ri ng a-ring loint lonque a-ri ng
(cx ternn l ports) {Svstemanschl iisse} (o r i fiee~ !;:1S1!il:rnc::!l (;lpenure eS l erD ~)
476 5' Bnck-up ring SlUtzring Sague anti-extm sion Anello ant ies tmsionc
(Q:ilinder el ld cn p) (Zvlindercnddcckel) (chapeau d'extrcmit e du vcrill) (cn UQell o leSHt eilind ro)
479 2 Steel plug Stahl stop fe n Bouehon aei er Tnppo di acciaio
(vil lve housing} (Ventil gc!lnllse) (c hnmbr~ d ~ valve) (cur[!O valvQla)
482 I' O-ring O-ring Joint tOriqllC O-ring (corn ice sede valvola)
(wl lve hou sing sun"Ollnd) (Ventil gch:tusc-EinfaS!iun g (cnveloppe du l (}" enl~ l l l UII: "il ly\:) (cQl"lli l.:!< sede ~'a l vQ la)
483 5' Piston seal backing ring Kolbcn-StIIlzring Baguc de renforcemcnt Anello di supporto fa scia cl<l stica
du jQi nt t!!;: ni ston nistone
484 Ke:i Pallfeder Clavette Chinvcua
48 ~ Wa ~ her. long I fI ~ e r shaft Un lerlcl! scll!t: ihe" R o ncl ~ ]l !;l arbre cOlligu!;; lono R Q T1Q~l1a albero rastre mntQ ItUl QO
lan ger kegcli ger Schnft
486 ~ut. taper shaft Mutter kcgcli!1 cr Schnft EefOn arbre conigue Dado albero raslremalo
7Q~
Splil pin, long taper shaft Spli nt, langer Goupi llc fe ndue, Coppig lia, albero rastrcmato
kegeligcr Schnft arbre conique long lung
P AQF. 50, [) ATA SHEET OHM- IOOI -?107.01

l re - J,:odificat ion
1. Preparations
If winch is under l oad ( anchor
IFIG 1 1 cable or rr,ooring rope out ) ,tight
band brake carefu l l y and disengage
the clutch if pos sible .
Befor e r err,oving the valve end cap
clean the areas carefully.
2. Removing oldham coupling

Open valve end cap .
lHthdral,o! the di st r ibutor
spool f r om val ve house .
Remo\'le oldham coupling, i f it
is broken all loosen parts mus t
be car efully col l ect ed.
3. Inspections
Val ve spool sealing rings should
be a smooth sl i di ng i n their
respective bores. Components ",.'hic h
ar e slighly scor ed are genera l ly
IFIG 2 1 re -usable .
Va l ve house cylinder bore should
be i nspect ed for s i ngs of \·Jear .
A Oldham coupl i ng to be cheched that
',.,ear on coupling tongues does not
all ow more than +/-Prelative
movement between va l ve and crank shaft .
1. Assemli ng
Fit t he oldham coupling onto groove
of crankshaft central ise it carefully
,·,i th help of gr ease . I t helps a lot of
assemb l ing i f the groove i s t urned
horizontal position.
= Note t he pos i tion of Teo .
'"
rl
Oldham Cou plin g Using the compr essor tool , i nsert the valve
"- spool into i t s house wi th a smooth movement.
If) Val v e s p ool I'lhen the spool end i s same l evel I,o., ith house
check that spool i s f r ee to rotate .
Turn the spool TeD mar k matching t he mark
on the crankshaf t and push the spool into
1 FIG the s lot.
Not e i f the spool is assembl ed in the
oppos i t e pos ition, i .e . 180° out, the
motor will rotate oppos i t e direction .
Place t he val ve end cap onto the house and
check t ha t there is no gap bet\·,een the house
and t he end cap. Tight en the bol t s, torque
35 Nm.
Stamp " L " 5. Put t ing int o oper ation

Start a pump and rotat e the motor slO\\lly
t·la rk L i s st amped on val ve end cap, to haul-in di r ection. Di sengage the clut ch
if direction of rotation i s changed at if it is engaged . Check the rotation direction
fa ctory - Teo marks on crankshaft of t he motor, pu l l the l ever - drum haul i n
and valve spool ar e 1800 out . and push the lever - drum payout .
If not cor r ect , \·!ithdra\·m the spool about 15 mm
and turn i t 180° .
CAUT ION
rl ron9 rot ation direction means that the winch is
Compression tool on page 2 not capable t o hold load .
Rauma twlEIIA FIIU""O L10 SERVICE I NSTRUCTIONS

DSI
I-:T~'=-S-'!O~::-:"::':~I;':G~1;":O=URH!2':::RO~~:::P.,~yS'-+"-sc--;al""'e- - - - I
OLDHAM COUPLING STAFFA
I T IS IlOT 'IO BE REPRODUCED OR
SHC....11 TO ~JlY THIRD PARTY
WITHOUl OUR SPECIAL PEPj,lISSIOU.
1 : 1 Group Size Serial nurclJe r Rev. Lar.g. Page
f-::.0'-,'.-;,n.,-9-;9_o_52_6_ _P_I J_ _ _ +.A

/:eight kg
1lVa
,., .__ _---1
"'pp,,':;:O'";-d_
Checked PIj
64 03575 OUOI
IU- /·;o dificatiol1
D O,5xO , 5 CHAMBER
A B C D
76 ,4 5
A8255455 FM3 ~O
~O.
.10
05
100 76, 2 38,1
101.85
A8255456
FM4 ... 0.10 125 101. 6 50,8
.. 0.05
Rauma
WIN C H E 5
K;}IE~A FItI[)~D LTD SERVICE INSTRUCTIONS DSI
C:r=H]':-S-=0''-::'''''-:-::'
II=-:G-:: sc-'-'al-e- - - - - I
]S""O=UR'"""='O=PE=R!:7'y,'-t-7 COM PRE SS ION TOO L STAFFA
IT IS IIOT TO BE REPRODUC ED OR
SHe;..":! TO ~J!Y THIRD P.\P.TY
WI THC\!T OUR SFECIAL PEPlIISSHlll.
1 1 Group Size serial nuriler Rev. Lar.g . Page
Dra:.n 990526 prJ Approved
/-;;:-·,:"='9 ed -
ht -;::'"'9------t-;c=heck:-c;- -1 64 03575 OU02
1 2 3 4 5 6 7 8 9 10 11 ,--------;1 2
. HANDeD RIGhT HANDED
12 "-
11 ./. . . . _._._. _._. _.-............... r ./
'\
A , / '\ ,
'\
'7 '\ (~ 11
i
/
\ ---~~
\ \
B
\
\
.-
\
1
....".
~~®~ g/
SECTION C - C
7
~o tim
@ HA-:ocking device Btl Un
~----@
~o N11I
", 1'
~", T ", T
SECTION A- A SECTION B - B
MOUNT!!IG BCLS 4_2 pes.1
(' co::: H"fOl1 .'!'SSF.KIIl.Y dno
150 Il!r. MOl,."NTING BOLTS 3 - ~ pes ,
~®-
~"e iIY:lR • .:.sSENBi:! d~
:50 );;:0
~~ . I. ,;.
EI H
at] - , ./, .. , L
"
! ~ <eI<:r YII~
' "' \
MPl i b flP11 \'!£
FI
0
tJ ~ rI'¥" t':\- ~ -~ f) 1f) 1 I". V5
o
~.
B~ I CO N",
3
n B
GI I V:3
100 1\..,
OULY ?ilRTS SHm.'N IN THE PART LI ST
~
ARE iNC"'..tJD.::l :n lUNCH VALVE DELI VERY.
'''
"1.. ......
"""" "t "'"
.... ''''',...", I"",,,
,.",.,1.'''''
:m.
' ~"',
,=
I Rolls-Royce .
l<olls·J:'oyce dec k r:ac,'in~ry
lrl ..· X" ell • ..:c'> • ...,..",'"
E"" " 1<0· ~ WINCH

.,~
00.1f,: :um ... 1. ... . . I~S VALVE

H =0::;; PI } 'V- 32P- -- F32 4 3:P
'!,.I .....l ~,.. ••
;''" I "'" 1 ~"' .. rI'".e~ I wr. "'<~:tj'"t ; ""

I
1 2 3 4 I 5 6 7 8
[LEfT HANDED I IRIGHT HANDEDI
A
wINe VALVE NG 32 WI NCH VALVE NG32 In NeH VALVE NG 25
HYDR. "IOTOR FM4 HYDR . MOTOR FM4 H'iDR . f-1QTOR FM 3
M1 6, 4 pe s M1 6, 4. pes Ml6, 4 pe s
Nm 100 Nm
c
M16 , 4+ 3 pes
150 Nm
rn>- IPLUG HOLES BY PUTTY
ALLEN BOLTS ALLEN BOLTS ALLEN BOLTS
BOTH HYRD . MOTOR AND WI NCH VALVE

D ~ CONTACT SURFACES MUST BE CLEANED
BEFORE ASSEMBLING .
GIVEN TIGHTEN ING TORGUES ARE FOR OILED
OR GREASED BOLTS.
TOLERANCES ~ O I+ lO Nm
~ ALLEN BOLT STRENGHT CLASS 8 . 8

HEXACON BOLT STRENGHT CLASS a. 8
E
nilS ii:u'W':; IS
11 l~ H{)T 1Q e.
Sl-OO 70 ill/ nn ~ p;.r.y
c:.;~ PRcmm
R Er R~~Cl:C ~
1I: 'MIOtT em: s~oc1.:.L P1FJ'1ISSI(I:C .

I S:a:.s
v I Rolls-Royce I Roll s -Royce deck ma chinery

,,- 9 110~ 19 PIJ S<21e
ASSEMBL ING INSTRUCTIONS DA l
1:1 0
Cl\e ~);ed 10032 6 pi j W'!i;:-.t t;
;'FJlrO':ed : 00326 .," WINCH V~~VE BOLT TORQUE WINCH VA
F G:'t1JrlS! : e IS~ ~i31 ~:JI"J:e r ,eo,' , V.l riar.t. f,'lQ~ Tota! fA~~~ I LGn~
~~+=~~~QC~[[=+]]~~I~~~l[CQ~~~"~;G]£D~,J~~o~'Epl]O~O- }j~~'L~~[2j!['~KIT~lrTIE'============================~ ~"ml ;~~ ;i:iI8 3 0 111 61- IEH 0 0 010 110 l iD
::e:o f.:odi ficdti on
1- --.J
VALVE CONTROL COVER HYDR_ REMOTE CONTROL
ASS EMBLY PILOT CYLI NDER
sc 1::11 so III: I
I 31 2S 2 '""
9 14 I 1 00 "'1'1
14 13 5 6 111 8 10 30 19 12
1)
CODE A667 9236 I NCLUDES
TWO COMPLETE PI LOT CYLINDERS
ITEMS 10,11 , 12,1 8,19,3 0
2)
~ CODE A667 9851 I NCLUDES
ITEMS 2,7, 8,9, 14, 17,2 0,21
24,2 8,29,31
rn:.. CODE A667 9819

J)
I NCLUDES
IX3I
ITEMS 4 ,5, 6, 13,23
H • HYIlP . R[MI)TE CO NTP.O:'

M • toI.\NtJAL CONTR OL
4 26 27 16 21 15 26 27 23 3 24
R3 50 11m (\ "':11 R4 SO Nm 50 l it!! SO 11m
E o / ~ 0
I
I
'i
'"
E-<
~'C v!~( ~ riG 01

\ r n - - ---~~
24 20 8 29 28 21 7 17 1 VI '
ISO11m 100 11m 1< .. Mir- -~
I RS
v v ,
VALVE CONTROL COVER
I r .....
I >~ _ _
- - -
_ _>~
.....'
..J -'
I I ~~ ...':..:::,,:...:"'" C IIIi1I nOI15-noyt:e Rolls -Royce dec k machl:'l!!ry
ASSEMBLY ~ I P~ ?31 ~ La drwg 29554 9 : '... c:m~ P;J .Ia·"l'l HYDRAULIC VALVE IT.~
.. O!O,~ . "I; ... ..... l '
ii -, X.J _ _ , _. _ _
'
. .JQ. -:l .J
jI WEl(;1Ii w 27 kg >ern< U"", . DIRECTION VALVE 32P
"r:!,j ,,_, ''',
3: ?
-" ,,". 1,;,/>'
1 2 3 4 5 6 7 8
-+-
A
D
TYPE
06
$ $ , ' - - -rol
I I
r---
':
-ffi- ]
B 7 I
5
n I
V8
30 Nm
15 .9 bar "I
L. _._~
8 r
9 6 150 Nm
V7 2
c 50 Nm
$ T2
$ 4
3
T
D
RoJls-~oyc e !ji AD
Lo drwg 396870
WEIGHT 0 6 kg I
C:~d:M
mm ... I 101 HYDRAULI C VALVE UN I T KHV
. . "t,b< " RETURN BLOCK NS32 - 06 RETURN
F
o 144 3,-
L .J
1 2 3 4 5 6 7 8
A lOONm 30Nm lONm lCNm 90Nm 9.2 1

r· - f~ ,_.- 1-,
I.JiII:- V10 I
t---~+ 1
.~
14.1
NOTE!
B Setting pressure is
shown i n hvdr . scheme
1 - - 3.1
V9 ll"" I
c V6
Pt:
;
L. _. ._ • ...J
R1K~ 1\ 1423110]
fS.'~'.~J: COR::CTIm mSrG:u
D O 'F, :~iJ
O·?!l;G
"
II 4Ulxl.53 ·90
U :xl.iHO
12
O-RlIf~ 11 59.33x2 .62 · 9\
O-Rll!G lC 66.3r.2.£2 ·90
CH::::'; V.UVE V~.HA~JD j A~5S(iOa.j
~('?EW RF.161:00
PLJ:> TJClmO
PL~~ ~mHOi)
?lWT roT::? 1957JiOO
11 14 3 7 2 15 10 ~ESt1E F.~L :Ef 'I}.:"'I':. FP.£Ul6J ~or P?stJl€09 ~E679;37 P502:C bar cr ~.m ~: ~s os 0 !~a :.ar
E l ON~ n ONo f'?LS'S~~.E EEL:E ~ ~t}J'\S P~U : 6Ql ~~mm
co~mEF.E.L!.NC; \l.~1\1: 2 l;~5m .~~6i95~ 5
TIGHTEN WITH 32mm ~.£~ Hio~li?C:..c BHmc

HEXAGON KEY pes TITLE f~RI TYPE SPARE CODE NOTE
KHV
Lo drwg HYDRAULIC VALVE UNIT
W 1 N L H t.. ~
'I'm Ja;..wIlJ:; IS C'.7 ~I"EY.'Y, Seille BASE BLOCK F32 4L F )2 "
n IS It:r. TO ~~ H, PO::Ucr:c CoP L
S1(OI.-1l TO ; ;1'1 'l"r! IRD ;>A?:TI 1 .2 I
F 3 10060; PIJ FIe TiEu ITEM 14 CHAKGD, I:2}I 13 ~DD:O ~l -:-mi OUI' SPCCI;J, ~n~:ss:~. • G:Ql.lrls: : e S~:':: al r.~ri:>e: l'!v. La~. Pm
A 030206 PIJ m Nal1'\ D~.i':G UmAED Ow'r. OOCS 10 ?lJ ~Pt:o·.. ed ~~Jil ) I
i~~ a.Jte Dralr.l Che ck ,l.ppr . p'(J(!ificilt::O,~ '~i9r.t 1·3 54 Cl'.~e~ed P!.j 81 3 0 1 4 6 4 - B U 0 0 0 0 1
1 2 3 4 5 6 7 8
l OOljll1 JONm JONm JONm 90NIT.
A 6 9.1 1 13 9.2 4 12 5 8 9.2 1
r' - ~ _.- 1-,
'J.2 ~i V1 0 I
+-----~t !
t..----_ ~F1
. ---IU
NOTE !
B Sett i ng pr essure i s
shown i n hvdr . sc heme V5
l---- 9.l
V9 ,f.,;";: I
c V6
?2.1
,
L_ ._ . ...J
/-" 1 ME.:"SURE ro;~Ci'i O:; 1l f1ISTG142

D //-,,\
1 O-RIII':; 13 ~ 7.2 ll: :.53 · 3~
I ( I I 1 o-Rm} 12 9. 2Sx1.78-90
\ \ / /
,,'- '-
/'
1
1
O·RTNG
O·Rm~
11
:0
59 ,9912.62 -gD
66 ,31.2.62 -,0
2 CE~CK VALVE 9 VW.OOO l n :800ii4
j SG.ElI' 9 P3161l0J
1 PLUG 1 !1'jJ340G~
: ~\k ; 44 l2mO
E
1
1
P!LOT CO'lEl
P?ESSUiE RCE? vms , 39571;nG
~F.SUl60c()r HSCl6a, ~.6675:B 7 ps=25r] bar or M679SaUS = J~C br
1 PRF.S5URE PiLEi' V~.LVE J ?f,SUl607 ~.6 m : c 9
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Kawasaki Staffa Radial Hydraulic Motors

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Kawasaki Staffa Radial Hydraulic Motors

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Kawasaki

srAFFA RADiAL P ~ STON

70 SERIES OVERHAUL & MA INTENANCE MA NUAL.

Kawasaki Preci sion Machinery (U K) Ltd,

Tel: +44 (0) 1752 364394

Copyright © Kawasaki Preci sion Machinery (UK) LTD.

PAGE No. PAGE CONTENT.

4 Screw thread torque requirements

6 Restrictor Screw Identification

10 Di sassembly of ' 8 ' type 7* series motor.

16 Assembly of '8' type T seri es motor.

27 Disassembly of 'C' type Y series motor

34 Assembly of'C' type 7* series motor

47 Exploded diagram & component identifi cation li st for '8'

49 Exploded di agram & component identification list for 'C '

Bas ic 'B ' Series Ordering Code

[2] MODEL TYPE

[3] FRAME SIZE

[4] SHAFT TYPE

[5] MAIN PORT CONN ECTIONS

[6] TACHO I ENCODER DRIVE

[7] DESIGN SERIES NUMB ER

[8] SPECIAL FEATURES

STAFFA PAGE 2 DATA SHEET

Model Code. (continued)

Bas ic 'C' Series Orderin g Code

F11 - HM*C - 200 - S3 - 188 - 90 - FM4 - CS - TJ( - 30 - PL**

[2] MODEL TYPE

[4] SHAFT TYP E

[5] HIGH DISPLACEMENT COD E

[6] L OW DISPLACEM ENT COD E

[7] MAIN PORT CO NN ECTION S

[8] DISPLACEMENT CO NTROL PORTS

[9] TACHO I ENCODER DRIVE

[10] DESIGN SERIES NUMB ER

j [11] SPECIAL FEATURES

STAFFA PAGE 3 DATA SHEET

._.-._-_. _-_.--_._--------- - _._- - - ------ - ---_._- -- -~--~ .--- - _.._ -----

1/4 " UN F 1 UN C 13 +/- 2 18 +/- 3 9 +/- 2 12 +/- 3

M6 10 +/- 2 14 +/- 3 9 +/- 2 12 +/- 3

Values are based on followin g materials:

- - - - - - - ~-- -- .. - ..,- . _.---,. -- - -- - - ----- - -- --

1/8" SS P M10 5 +/- 0.3 6.8 +/- 0.4

STAFFA PAGE 5 DATA SHEET Hydraulic Products

R estrictOl' Screw Ide nti ficatio n

Res trictor Screw Id entification T able

Rcs trictor Fa c e Id e ntific a tion M arks S ize T hr ea d S i z e

1 x Circl e .015" 711 6" UN F

2 x Circl e .02 1" 7/1 6" UN F

2 x Circl e and X .028" 711 6" UN F

Pl ai n Fa c e & X .0 40" 7/1 6 " UNF

Plain Fa ce & Groov e at Nose End .01 9" 7 /1 6 " UN F

Pl ain Fac e .5mm Bmm x 1. 25p

R estrictor Torqu e Requirements

Care must be taken to ensure th e restrictor hol e remains clear.

F atl lt Diagn osis.

2. Re li ef val ve in th e circ uit is not Se t valve to the cor rec t va lu e.

3. Se iz ur e of movin g part s. Insp ect motor intern ally and replac e

5 . Con · ro d restri ctor block e d Re pla ce a ll restri cto rs .

necessa ry parts with neVI.

STAFFA PAG E 7 DATA SHEET

in re ver se d i r ec tion . bee n co nn ec ted in reve rs e .

a li gned with th e cranksh art . crank sha ft .

2. Te mperatu re too high ca us ing Re duce oil temp eratur e.