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.

(11) △ ! CAUTION When dropping the anchor by using brake device, stop
dropping the anchor every half shackle absolutely to avoid
over speed and chain hunting.

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

CHAPTER 2. SPECIFICATION & DRAWING

2-1. RULES......................................................................................................1
2-2. EQUIPMENT LIST.......................................................................................1
2-3. PARTICULARS...........................................................................................5
2-4. MATERIALS OF MAIN PARTS.......................................................................9
2-5. SPARE PARTS AND SPECIAL TOOLS............................................................9
2-6. PAINTING.................................................................................................10
2-7. HYDRAULIC FLUID AND LUBRICANTS..........................................................10
2-8. DOCUMENTS TO BE SUBMITTED................................................................11
2-9. NAME PLATES..........................................................................................11
2-10. GUARNATEE...........................................................................................11
2-11. SHOP TEST PROCEDURE.........................................................................12
2-12. DRAWING
(1) WINDLASS...........................................................................................13
(2) BELL MOUTH.......................................................................................19
(3) MOORING WINCH.................................................................................20
(4) PUMP UNIT..........................................................................................30
(5) ELECTRIC MOTOR................................................................................33
(6) STOP VALVE........................................................................................39
(7) STARTER (FWD)...................................................................................40
(8) STARTER (AFT)....................................................................................53
2-13. LIST OF SPARE PARTS AND TOOLS...........................................................66
2-14. INSTRUCTION FOR INSTALLATION............................................................102
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. STARTING AND WARMING UP OPERATION FOR THE HYDRAULIC PUMPS
3-6. OPERATION OF WINDLASS AND MOORING WINCH
3-7. STOP OPERATION OF HYD. PUMP
3-8. SAFETY DEVICE
3-9. CAUTIONS
3-10. ADJUSTMENT OF THE HYDRAULIC EQUIPMENT
3-11. 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. PUMP UNIT AND FILTER
4-6. OIL COOLER
4-7. OTHERS
4-8. INSTRUCTION FOR REPLACING THE BRAKE LINING OF BOLT-NUT TYPE
4-9. MAINTENANCE ON FAILURE OF HYDRAULIC WINCH

CHAPTER 5. TROUBLE SHOOTING LIST

CHAPTER 6. DETAIL DESCRIPTION OF MAIN PARTS

6-1. HYDRAULIC MOTOR

6-2. HYDRAULIC PUMP

6-3. COUNTERBALANCE VALVE
6-4. CONTROL VALVE
6-5. REGULATOR FOR HYD. MOTOR
6-6. RETURN FILTER
6-7. OIL COOLER
6-8. FAIL-SAFE BAND BRAKE

CHAPTER 7. ASSEMBLY DETAIL

7-1. WINDLASS
7-2. MOORING WINCH
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.

COPYRIGHT FLUTEK, LTD

 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.

COPYRIGHT FLUTEK, LTD

 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.

COPYRIGHT FLUTEK, LTD

INSTRUCTIONS MANUAL

CHAPTER 2.

SPECIFICATIONS & DRAWING

COPYRIGHT FLUTEK, LTD

 1

1. RULES
LLOYD'S REGIESTER OF SHIPPING (LR)
KOREAN INDUSTRIAL STANDARDS & MAKER'S STANDARD IN DETAIL.

2. EQUIPMENT LIST
2-1. SCOPE OF OUR SUPPLY
ITEM NAME DESCRIPTION Q'TY DRAWING NO. PAGE

10 LEFT TYPE 1 FMW31-11102D

WINDLASS 335.2 kN x 9 m/min
11 RIGHT TYPE 1 FMW31-11103D
CHAIN PIPE HEAD φ84, GRADE3 2 FMW43-4683
12 LEFT TYPE 1 FMW31-11111C
13,15,17 MOORING WINCH 196 kN x 15 m/min LEFT TYPE 3 FMW31-11112C
14,16 RIGHT TYPE 2 FMW31-11113C

30 PUMP UNIT(FORE) H402PON 1 FMW31-11738

31 PUMP UNIT(AFT) H402PON 1 FMW31-11114A
ELECTLIC MOTOR 90KW-4P 4
60 FAN COOLER UNIT 2 FMW34-11132A

70 STOP VALVE SF280-20SW 2 FMW32-11626

FORE GROUP STARTER 90KW-4P x 2 (Y-△) 1set HTKFD-90K

80
R.P.B WITH PROTECTION BOX 1set HTKFD-90K-R2
AFT GROUP STARTER 90KW-4P x 2 (Y-△) 1set HTKAF-90K
81
R.P.B WITH PROTECTION BOX 1set HTKAF-90K-R2

90 BRAKE TEST KIT 1set FMW33-9355

SPARE PARTS AND SPECIAL

- Manufacturer's standard 1set FMW45-4449
TOOLS

2-2. OUT OF OUR CONTRACT

PART LIST OF HYD. CIRCUIT DIAGRAM
ITEM NAME DESCRIPTION Q'TY REMARKS

1) Anchor, Chain cables, mooring ropes and chain stopper.

2) All piping materials and works
3) Elec. Wires, connectors, other wiring materials and wiring works.
4) Installation.
5) Hydraulic fluid and lubricants.
6) Others not described in this specifications item 2-1.
2
3
4
 5

3. PARTICULARS
3 - 1 WINCHES

WINDLASS (ITEM W1, W2)

DRUM CHAIN DRUM MOORING DRUM WARPING END

UNIT
(Rated point) (Layer) (1 st) (1 st)

Winding load (over load) kN 335.2(502.8) 196 196

Winding Rated m/min 9 15 -

speed No load m/min abt. 30 abt. 45 -
W1 : HWLC084U3K200D2W1
Type
W2 : HWRC084U3K200D2W1
Right hand type = 1 <W2> Total = 2
Quantity Set(s)
Left hand type = 1 <W1>
Dia. (Grade) Φ mm 84 (GRADE3) - -
Chain
Shackle Kenter - -
Dia. (Type) Φ mm - High modulus synthetic
Rope fiber rope -
Length m - Φ34 x 220m
Diameter Φ mm - 550 450
904(Split type)
Length mm - T-side : 460 500
Drum S-side : 425
Flange dia. Φ mm - 1300/1500 -
Quantity Piece 1 2 1
Ratio 25.24 5.27
Gear Spur gear, Spur gear,
Type
Open (with cover) Enclosed

MBL : 824 kN
(1st) PCD 584
(Layer)
Capacity
kN
2323 [MBLx80% = 659.2 kN] -
Brake OPERATION :
[MBLx60% = 494.4 kN]

Manually
Operation Manually
(Spring applied fail safe)
-
Provision Equipped -
Clutch
Operation Manually -
Type * Q'ty per set HMJC270T/ 250 /80 * 1

Hyd. Speed rpm abt. 230 / 149 (at no load)

Motor Effect. Press Mpa 14.7 19.7 -
Required flow L/min 310 200 -
Autotension device Not equipped

Chain counter Not equipped

Notes Warping end To be without whelp
Winding direction
Shown in the drawings
and fastening method
Weight / Each 11.3 ton
 6

MOORING WINCH (ITEM M1)

IN CASE OF USING
DRUM MOORING DRUM WARPING END
SPM DRUM
UNIT
(Rated point) (Layer) (1 st) (Last) (1 st)

Winding load (over load) kN 196 147 196

Rated m/min 15 15 15
Winding
speed
No load m/min abt. 45 - -

Type M1 : HMWL200D2W1

Quantity Set(s) Left hand type = 1 <M1> Total = 1

Dia. (Type) Φ mm High modulus synthetic

Φ34 x 220m /
Rope fiber rope -
Φ80 x 150m(SPM)
Length m Φ34 x 220m

Diameter Φ mm 550 550 450

904(Split type) 1229(Split type)

Length mm T-side : 460 T-side : 460 500
Drum S-side : 425 S-side : 629

Flange dia. Φ mm 1300/1500 1580 -

Quantity Piece 1 1 1

Ratio 5.27
Gear
Spur gear,
Type
Enclosed

MBL : 824 kN
(1st) PCD 584
(Layer)
Capacity [MBLx80% = 659.2 kN] - -
kN
Brake OPERATION :
[MBLx60% = 494.4 kN]

Manually
Operation - -
(Spring applied fail safe)

Provision Equipped
Clutch
Operation Manually

Type * Q'ty per set HMJC270T/ 250 /80 * 2

Speed rpm abt. 149 (at no load)

Hyd.
Motor
Effect. Press Mpa 19.7 - -

Required flow L/min 200 - -

Autotension device Not Equipped

Notes Warping end To be without whelp

Winding direction
Shown in the drawing
and fastening method
Weight / Each 5.2 ton
 7

MOORING WINCH (ITEM M2~M6)

DRUM MOORING DRUM WARPING END

UNIT
(Rated point) (Layer) (1 st) (1 st)

Winding load (over load) kN 196 196

Rated m/min 15 15
Winding
speed
No load m/min abt. 45 -
M3, M5 : HMWR200D2W1
Type
M2, M4, M6 : HMWL200D2W1
Right hand type = 2 <M3, M5> Total = 5
Quantity Set(s)
Left hand type = 3 <M2, M4, M6>

Dia. (Type) Φ mm High modulus synthetic

Rope fiber rope -
Length m Φ34 x 220m

Diameter Φ mm 550 450

904(Split type)
Length mm T-side : 460 500
Drum S-side : 425

Flange dia. Φ mm 1300/1500 -

Quantity Piece 2 1

Ratio 5.27
Gear
Spur gear,
Type
Enclosed

MBL : 824 kN
(1st) PCD 584
(Layer)
Capacity
kN
[MBLx80% = 659.2 kN] -
Brake OPERATION :
[MBLx60% = 494.4 kN]

Manually
Operation
(Spring applied fail safe)
-

Provision Equipped
Clutch
Operation Manually

Type * Q'ty per set HMJC270T/ 250 /80 * 1

Speed rpm abt. 149 (at no load)

Hyd.
Motor
Effect. Press Mpa 19.7 -

Required flow L/min 200 -

Autotension device Not Equipped

Notes Warping end To be without whelp

Winding direction
Shown in the drawing
and fastening method
Weight / Each 4.7 ton
 8

3 - 2 PUMP UNIT

PUMP UNIT (ITEM 30, 31) [For FORE & AFT Group]

TYPE H402PON
UNIT

Quantity Set(s) 2

Type x Q'ty per set K3VL 140 x 2

Working pressure MPa 21.7

Hydraulic pump
Required delivery L/min 200 x 2

Relief valve
MPa 23.7
setting pressure

Voltage x Hz V x Hz AC440V x 60Hz

Power kW 90 kW x 2

No. of pole - 4

Rating - Continuous
Electric motor
Protection class IP44

Insulation class F

Space heater Equipped (Element type)

Rated voltage of
AC220V,1 phase, 60Hz
space heater

Fan cooler(FORE) Ambient temperature in bosun store 45°C

Fan cooler(AFT) Ambient temperature in S/G room 45°C

Level gauge Visual detector

Accessories Float switch Low level shut down

Thermometer Visual detector

Thermoswitch High temperature shut down

Filter Visual clogged indicator

Weight / Each 2.8 ton

<NOTE>
The pump unit shall have enough capacity for each of the following case.
ㆍFORE-GROUP (Opeating two pumps)
1) One (1) cable lifter (100% capacity x 100% speed) or Two (2) mooring winches ( 100% capacity x 100% speed
ㆍAFT-GROUP (Opeating two pumps)
1) Two (2) mooring winches ( 100% capacity x 100% speed)
 9

4. MATERIALS OF MAIN PARTS FOR DECK MACHINERY

NAME MATERIALS

Chain wheel Carbon steel castings

Main drum Rolled steel for general structure

Shaft Carbon steel for machine structural use

Gear Carbon steel castings

Pinion Carbon steel for machine structural use

Bed & Frame Rolled steel for general structure

Bearing metal Bronze Casting (Copper Alloy Casting)

Warping end Cast iron

Brake drum For chain drum SUS304 Overlay welded

(surface)
For mooring drum SUS304 Solid plate

Brake band Rolled steel for general structure

Brake lining Non-Asbestos

Grease nipple (Ball type) Brass (PT1/8" : JIS B 1575) BALL TYPE

5. SPARE PARTS AND SPECIAL TOOLS

Brake lining 1 piece for each size

Grease nipple 6 pieces (ball type)

Oil seal and O-ring for hyd. motor and hyd. pump 1 set for each type
Spare parts
Spring and O-ring for relief valve 1 set for each type

Strainer element 1 set for each type

Bearing for elec. Motor 50% for each size x no. of motor

Grease gun 1 set

Special
tools
Special tools Manufacturer's standard

See spare part & tool list in detail.

 10

6. PAINTING
IN-DOOR
NAME OUT-DOOR
ELEC. PANEL

EP 1760 Alkyd resin zinc chromate

Under coating ------- 1 coat (100 μm x 1) and iron oxide primer
Color: GREY 1135 -------2coats ( ≥70 μm)
RAL 7032

SIGMACOVER456 Alkyd resin enamel

Finish coating & color ----- 1 coat (100 μm x 1) ------- 1coat ( ≥35 μm)
Color : CMP GREEN CS-519 7.5BG 7/2 (Blue Green)

Paint maker Manufacturer's standard

Detail method Manufacturer's standard

7. HYDRAULIC FLUID AND LUBRICANTS

QUANTITY
KIND OF OIL
FORE AFT

Hydraulic fluid or Anti-wear type Except oil in the piping

Working oil * hydralic fluid.
ISO VG46 ~ VG68 or equivalent
1,200L 1,200L

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.95x4=380L abt.95x4=380L

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

 11

8. DOCUMENTS TO BE SUBMITTED
For approval For installation Finished plan

Specification & Drawings 15 12 7

List of spare parts and tools 15 12 7

Records of the shop test - - 7

Instruction book - - 7

9. NAME PLATES

KIND OF NAME PLATE LANGUAGE

Caution plates English

Other name plates English

10. GUARANTEE
We will repair, renew or replace only the defective parts of the equipment which were caused
by defective design, defective material or poor workmanship on our account within tweleve (12)
months from the date of ship's delivery or eighteen (18) months from the date of delivering
the equipment, whichever is earlier, unless the equipment has been subject to misuse,
improper installation, inadequate maintenance or accident.
 12

11. SHOP TEST PROCEDURE

The following tests (1) ~ (4) are carried out.
The tests of windlass are carried out in the presence of LR surveyor.
The LR certificate is submitted.

SHOP TEST SHALL BE CARRIED OUT AS FOLLOWS :

[○] : TO BE TESTED IN THE SHOP
[SHOP TEST]
IN THE PRESENCE OF THE
DESCRIPTION CAPACITY QUANTITY
INSPECTORS OF THE SHIPYARD.
QUANTITY SHOP TEST
WINDLASS 335.2 kN x 9 m/min 2 1 ○
MOORING W/H 196 kN x 15 m/min 6 1 ○
(SPM W/H - M1) 147 kN 15 m/min - - -
[NOTE]
(1) THESE MACHINES SHALL BE TESTED ACCORDING TO THE MANUFACTURE'S STANDARD
PRACTICE.
(2) THE TEST RECORD FOR THE ABOVE MACHINES SHALL BE SUBMITTED.

SHOP TEST FOR DECK MACHINERY

(1) LOAD TEST FOR HYDRAULIC WINCH
LOAD SHOP TEST RECORDING ITEM
IN EACH DIRECTION OF ROTATION - DRUM REVOLUTION.
NO LOAD CONTINUOUSLY TOTAL 30 MINS. - MAIN PRESSURE.
(MEASUREMENT : 1 TIME) - OIL TEMPERATURE.
PULLING AND SLACK REPEATEDLY - WIRE SPEED.
HOISTING
TOTAL 15 MINS. - MAIN PRESSURE.
LOAD
(MEASUREMENT : 1 TIME) - OIL TEMPERATURE.
RATED P.C.D. AT HOIST
NAME NOTE
(LOAD x SPEED) RATED POINT (LOAD x SPEED)
WINDLASS kN x m/min kN x m/min with equivalent load
1.RATED LOAD 335.2 x 9 1,090 123.7 x 23.1 on Mooring drum
2.OVER LOAD 502.8 x - 185.6 x - φ 550
MOORING kN x m/min kN x m/min On Mooring drum
584
WINCH 196 x 15 185.6 x 15.1 φ 550
SPM kN x m/min kN x m/min On Mooring drum
1,461
WINCH 147 x 15 348 x 6 φ 550

HOISTING RATED SHEAVE P.C.D. AT RATED POINT

= X X
LOAD LOAD EFFICIENCY [DRUM DIA.+TEST WIRE ROPE DIA.] x [i2]

HOISTING RATED [DRUM DIA.+TEST WIRE ROPE DIA.] x [i2]

= X
SPEED SPEED P.C.D. AT RATED POINT
* SHEAVE EFFICIENCY : 0.95
* TEST WIRE ROPE DIA. ø 36 ☞ i2 = 4.7917 : 2nd REDUCTION GEAR RATIO
* STROKE OF TEST CYLINDER : 3.5 m (For WINDLASS)
(2) BRAKE TEST
* CABLE LIFTER : THE BRAKE HOLDING LOAD TEST OF CABLE LIFTER IS SUBSTITUTED TO CALCULATION
SHEET APPROVED BY CLASSIFICATION SOCIETY AND ALSO THE BRAKE IS TESTED WITH THE ANCHOR
DROPPING, CONTROLLED AND STOPPED BY THE BRAKE
* MOORING DRUM : 1 SET TESTED ACCORDING TO <INSTRUCTION FOR BRAKE TEST>
(3) CLUTCH TEST
IT SHALL BE CONFIRMED THAT THE ENGAGEMENT AND THE DISENGAGEMENT OF THE
CLUTCH IS EASY.
(4) OVERHAUL
GEAR : AFTER THE SHOP TEST, THE CONTACT SURFACE OF THE GEAR SHALL BE
SUBMITTED.
<TEST EQUIPMENT> COUNTER CYLINDER - LOAD CELL
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 32
INDUCTION MOTOR 90 kW 4 P 250M
DATA SHEET
MODEL: I120HV1B3A CUSTOMER : COIL SPEC NO.: REV. NO : 0
APPLICATION: PROJECT NAME: QUANTITY : SETS
GENERAL DATA PERFORMANCE DATA
FRAME NO. 250M OUTPUT 90 kW
DRIP PROOF POLES 4 POLES
ENCLOSURE TOTALLY ENCLOSED ROTOR TYPE SQUIRREL CAGE
Increased Safety Exp.-proof D.O.L Y-△
PROTECTION IP 44 STARTING METHOD REACTOR ( %TAP) V.V.V.F
METHODS OF COOLING SC FC VECTOR-DRIVE
PHASE 3 PHASE RATED VOLTAGE 440 V V
SERVICE FACTOR 1.0 FREQUENCY 60 Hz
INSULATION CLASS F CLASS CURRENT
TEMP. RISE AT FULL LOAD (at S.F 1.0) NO LOAD A A
RES. METHOD 100 ℃ FULL LOAD 152.3 A A
THERMO. METHOD ℃ STARTING 990.2 A A
LOCATION INDOOR OUTDOOR EFFICIENCY
ALTITUDE 1000 m AT 1/2 LOAD %
HUMIDITY 80 % AT 3/4 LOAD %
AMBIENT TEMPERATURE -10~45 ℃ AT FULL LOAD 91.2 %
RATING CONT. %ED POWER FACTOR
NEMA DESIGN B AT 1/2 LOAD %
MOUNTING B3 B5 V1 B3B5 AT 3/4 LOAD %
BEARING TYPE BALL / BALL AT FULL LOAD 85.0 %
DE\N-DE 6317 / 6314ZZ SPEED (AT FULL LOAD) 1765 rpm
LUBRICANT GREASE TORQUE
COUPLING METHOD DIRECT V-BELT FULL LOAD 49.7 kg-m 100%
ROTATION(Facing Drive End) CW CCW LOCKED ROTOR 54.6 kg-m 110%
SHAFT BREAKDOWN 89.4 kg-m 180%
EXTENSION SINGLE NOISE LEVEL 89.0 dB(A)
EXTERNAL THRUST - VIBRATION 30.0 ㎛
TERMINAL BOX ALLOWABLE LOAD GD² REFERRED TO MOTOR SHAFT
MAIN STEEL AL CAST (AT DIRECT ON-LINE) 195.0 kg-m2
AUX. YES NO Motor GD2 6.6428 kg-m2
BOX LOCATION TOP (Viewed from Drive end) MOTOR APPROX. WEIGHT 540 kg
APPLICATION STANDARDS KS.IEC PAINTING MUNSELL NO. 7.5 BG 7 / 2
THICKNESS STANDARD 70㎛
ACCESSORIES (OPTIONAL) SUBMITTAL DRAWINGS
* SPACE HEATER YES OUTLINE DIMENSION DW-I120HV1B3A
RATING 1Φ 100W 220V SPEED-TORQUE CURVE ST-I120HV1B3A
* CABLE GLAND : 35b*2EA, 20c*1EA TERMINAL BOX DIMENSION TB-I120HV1B3A
* MUNSELL 7.5BG 7/2(epoxy)

NOTE REMARKS
1. THESE DATA ARE ONLY DESIGN VALUES AND SHALL BE 1. ABOVE ALL DATA ARE CALCULATED AT 100% VOLTAGE.
GUARANTEED WITH TOLERANCE OF APPLICATION STANDARDS. 2. JIS B1575A TYPE 1/8PT GREASE NIPPLE BALL TYPE.
2. OTHERS NOT MENTIONED IN THIS SHEET SHALL BE 3. REFER TO THE SHIPYARD POS.
IN ACCORDANCE WITH HIGEN MOTOR STANDARD. 4. CABLE : U-RED / V-WHITE / W-BLACK MARKING TUBE.
TE : TOTALLY ENCLOSED DP : DRIP PROOF DATE PREPARED CHECKED APPROVED
FC : FAN COOLED SC : SELF COOLED 2010-12-29 M.J.YU S.S.YUN H.T.KIM
A4(210X297)
33
34
35
 36

AC INDUCTION MOTOR DATA SHEET

Model No.or RFQ No. Item No. Rev. No. [ 0 ]
Project Name Project No. Quantity sets
GENERAL SPECIFICATION PERFORMANCE DATA
Frame Size 132M Rated Output 5.5 kW 7.5 HP
Type HS Number of Poles 6 sin
Enclosure(Protection) Totally Enclosed ( IP55 ) Rotor Type Squirrel Cage
Method of Cooling IC411(FC) Starting Method* D.O.L Y-
Rated Frequency 60 Hz Rated Voltage 440 V 380 V 220 V
Number of Phases 3 Current Full Load 11.1 A 12.9 A 22.2 A
Insulation Class F B H Locked-rotor** 600 % 600 % 600 %
Temp. Rise at full load (by resistance method) Efficiency
at 1.0 S.F 80 deg. C 50% Load 89.0 % sin
Motor Location Indoor Outdoor 75% Load 89.7 % sin
Altitude Less than 1000 meter 100% Load 89.5 % sin
Relative Humidity Less than 80 % Power Factor(p.u)
Ambient Temp. 45 deg. C (Max.) 50% Load 0.544 sin
Duty Type Continuos ( S1 ) 75% Load 0.667 sin
Service Factor 1.15 100% Load 0.725 sin
Mounting B3 B5 V1 B3/B5 Speed at Full Load 1165 r.p.m sin
Type Anti-Friction Torque
Bearing DE/N-DE 6208ZZC3 / 6208ZZC3 Full Load 4.6 kg·m sin
Lubricant Grease(Polyrex-EM) Locked-rotor** 180 % sin
External Thrust Not applicable Breakdown** 220 % sin
Coupling Method Direct V-Belt Moment of Inertia (J)
Shaft Extension Single Double Load(Max.) 13.000 kg·m2
Terminal Main Steel Cast Iron Motor 0.052 kg·m2
Box Aux. Yes No Sound Pressure Level (No-load & mean value at 1m from motor)
Location Refer to Outline Drawing 62 dB(A)
Application Vibration 1.6 mm/sec (r.m.s)
Area classification Non-Hazardous Permissible number of Cold 3 times
Type of Ex-Protection Not applicable consecutive starts Hot 2 times
Applicable Standard KS,IEC,NEMA MG1 Part30(Vpeak) Paint Munsell No. 4.0PB5.4/5.5(VL-451)
ACCESSORIES SUBMITTAL DRAWING
Outline Dimension Drawing \ Motor Weight(Approx.)
B3 227B2000AB04 70 kg
B5 227B2020AB04 74 kg
V1 227B2060AB04 74 kg
B3/B5 227B2040AB04 74 kg
Main T-Box Ass'y 227B8004CB

SPARE PARTS REMARK High Efficiency

＊ For use on PWM VFD 10:1VT, 3:[email protected]&F Temp. rise

Date DSND CHKD CHKD APPD

2011-04-14 W.H.BACK S. J. RA O. J. KIM J. H. KIM

Note: Others not mentioned in this data sheet shall be in accordance with maker standard.
Above technical data are only design values and shall be guaranteed with tolerance of applicable standard.
Inspection and performance test shall be maker standard, if not mentioned.
* In case of Inverter-Fed Motor, performance data is based on sine wave tests.
** Data is based on when the motor is supplied at rated voltage & frequency. and the data is expressed as a percentage of full-load value.

HHI W230-131-1 * In case of Inverter or V.V.V.F Motor:Performance data is based on sine wave tests. A4(210mm X 297mm)
 37

1-20c
38
 NO. DESCRIPTION MATERIAL Q’TY REMARKS

BODY SC480

1 -
FLANGE C.STEEL 2

2 -
0 RING NBR 2

3 -
BOLT SCM4 8

4 -
DISC S45C

5 -
0-RING NBR

6 -
BACK UP RING PTFE 2

7 -
0 RING NBR

8 -
BONNET C.STEEL

9 -
STEM SUS304

m -
¢140.0 0-RING NBR

n -
G머ND BRASS

띠 -
LOCK NUT BRASS

n -
HANDLE C.STEEL

냐 -
0 RING NBR

며 -
BACK-UP RING PTFE

NAME P내TE SUS316

머 -η -대 -
깨 WASHER SUS304
NUT SUS304

(X。ααα〈·zωα。)
。.‘”
。N

NOTE.
1. PART NO. : VHSF280-20SW-SC48
2. CONN. & SIZE : 32A JIS 280K SQURE F내NGE
3. DESIGN PRESSURE 28MPa at 38'C
4. MAX WORKING PRESSURE : 28MPa at 38'C
5. PRESSURE TEST : API 598
6. FLANGE DESIGN : JIS F7806
7. DESIGN TEMPERATURE : -2o·c ∼ 1oo·c
8. UNIT mm

35.0 150.0 18.0 9. WEIGHT : 18.4Kg

32A S.W 98.0

220.0 TYP.
106.0
0 1 15.APR.2014 1 ISSUED FOR APPROVAL S.W.SE。 J.K.PARK W.C.KIM

REV. I DATE I DESCRIPTION BY CHECKED APPR。VED

rLUfEKFLUTEK d.

TITLE
STOP VALVE
70
32A JIS 280K SQUR E FLANGE

FMW32-11626 0 I I N/S 1

PROJECT N。 DWG N。 REV. STATUS SCALE

I I CLASS PAGE
39
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45
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53
54
55
56
57
58
59
60
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62
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64
65
 66

SPARE PART AND TOOLS

OF
ELEC.-HYD. DECK MACHINERY

Hull NO. : S749/50/51/52/53/54/55/56/57/58

MESSER'S. FLUTEK, LTD

MARINE MACHINERY WORKS
GENERAL RESEARCH
1. SHIPYARD : HYUNDAI SAMHO ENGINEER
HEAVY INDUSTRIES CO., LTD. GENERAL RESEARCH
2. Hull No. : S749/50/51/52/53/54/55/56/57/58 ENGINEER
3. KIND OF SHIP : 84,000 CBM LPG CARRIER CHIEF RESEARCH
4. CLASSIFICATION : LR ENGINEER
5. OWNER : DORIAN RESEARCH

ENGINEER C.W.Ryu
DRAWING NO. : FMW45-4449 DATE : 2014. 01. 27.

F L U T E K, Ltd.
 67

CONTENTS
1.SPARES
NOTE NAME FORM REMARK PAGE
WINDLASS 335.2kN X 9m/min 1
MOORING WINCH 196kN X 15m/min 1
HYD. MOTOR HMJC270 2
REGULATOR FOR HMKC SR231/2/3 3
SELECTOR VALVE 4394-K10 4
10,11 COUNTERBALANCE VALVE KCB40/25EAE 5-6
12-17 CONTROL VALVE KWV22/32/42PS 7
STOP VALVE SVPH7350 8
STOP VALVE SVPH7340 9
CHECK VALVE HIC-FJ50 10
CHECK VALVE HIC-FJ40 11
CHECK VALVE HIC-FJ15 12

HYD. PUMP K3VL140/B-10RJM-PO 13-14

HYD. PUMP (HOSE) K3VL140 15
RELIFE VALVE RB30C-315 16
SOLENOID DIRECTIONAL VALVE DE6P-30-204-WA200AL 17
30,31 CHECK VALVE HICZ-FK32 18
CHECK VALVE C52F 19
RETURN FILTER FRs16 20
ELECTRIC MOTOR(FWD) 90kW-4P 21
ELECTRIC MOTOR(AFT) 90kW-4P 22

70 STOP VALVE HF-1280-32-* 23

FLANGE, THREAD NIPPLE SHA/SSA/LSA/STNL/STNTL 24

2. TOOLS
TOOLS FOR HYD. MOTOR TOOLS(HMC200, HMC270) 25-26
OVERHAULING TOOLS - 27

[ REMARK] SPARE PARTS AND TOOLS IN THIS LIST TO BE PACKAGED IN STEEL BOXES (REF. JIS 0902)
 68

18

10
 69
2
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3
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4
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5
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6
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7
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8
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9
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10
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11
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12
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13
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14
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15
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16
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17
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18
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19
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20
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88
 90
23
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24
 92
25
 93
26
 94
27
 INSTRUCTION FOR BRAKE TEST
L L
La Lb Lb La H1 : 650 mm
H2 : 183 mm
H3 : 800 mm
H4 : Confirm to yard
D D
(Brake test bracket : Shipyard supply)

H1
H1

H3
H3

H2
H2
H4

H4
DECK DECK

BRAKE TEST BRACKET BRAKE TEST BRACKET

(SHIPYARD SUPPLY) (SHIPYARD SUPPLY)

TEST PROCEDURES
1. Before brake test, check that the brake lining surface is continuously touched on brake drum.
2. Tighten the brake of testing drum surely and disengage the clutch.
3. Install the test kit with pins.
4. Put the hydraulic jack on the lower edge point of the test kit. Adjust the height of hydraulic jack on foundation.
During jack up operation, it is necessary to tight the brake handle again.
5. While paying attention to each part, raise the pressure by hand operated pump and read the scale of attached pressure gauge.
6. Brake holding capacity can be found the value gained from pressure gauge.
7. After the test is finished, operate it in the reverse procedure of above description.
NO. PART NO. PART NAME MAT'L Q'TY REMARKS

WARNING 1 BRAKE TEST KIT ASS'Y 1

Prepare a brake test bracket which is strong and stable enough to support the force. -1 BRAKE TEST KIT 1

After making sure that the brake test bracket is set on a level, operate the hand pump -2 HTD. JACK 1

carefully enough not to work off the brake test bracket. -3 HAND PUMP WITH HOSE 1

If the brake test bracket is worked off, you may encounter injury.
95
 L
CALCULATION SHEET La Lb

F Fj F X (D/2)
Pa = = 2 Fj =
A (3.14Xd/4) L

WHERE
Pa = Test pressure (Kg/cm²) D
F = Brake force (Ton)
A = Area of hyd' cylinder (mm²)
Fj = Hydraulic jack force (Ton)
D = Drum diameter + Wire/Rope diameter(mm)
d = Cylinder inner diameter (mm)
L (La+Lb) = Distance from center of drum till center of jack(mm)

DECK

MBL : 84 Ton
Drum diameter(Hawser drum) : 550 mm
Wire/Rope diameter : 34 mm
d : 95 mm FOR NORMAL DRUM
La : 185 mm
Lb : 530 mm
L : 715 mm MBL 60% (F) 50.4 Ton MBL 80% (F) 67.2 Ton
D : 584 mm Hydraulic jack force (Fj) : 20.6 Ton Hydraulic jack force (Fj) : 27.4 Ton
Test pressure (Pa) : 291 Kg/cm² Test pressure (Pa) : 387 Kg/cm²
96
 L
CALCULATION SHEET La Lb

F Fj F X (D/2)
Pa = = 2 Fj =
A (3.14Xd/4) L

WHERE
Pa = Test pressure (Kg/cm²) D
F = Brake force (Ton)
A = Area of hyd' cylinder (mm²)
Fj = Hydraulic jack force (Ton)
D = Drum diameter + Wire/Rope diameter(mm)
d = Cylinder inner diameter (mm)
L (La+Lb) = Distance from center of drum till center of jack(mm)

DECK

MBL : 84 Ton
Drum diameter(Hawser drum) : 550 mm
Wire/Rope diameter : 34 mm
d : 95 mm FOR SPM DRUM
La : 185 mm
Lb : 670 mm
L : 855 mm MBL 60% (F) 50.4 Ton MBL 80% (F) 67.2 Ton
D : 584 mm Hydraulic jack force (Fj) : 17.2 Ton Hydraulic jack force (Fj) : 23.0 Ton
Test pressure (Pa) : 243 Kg/cm² Test pressure (Pa) : 324 Kg/cm²
97
98
 99

SINGLE - ACTING CYLINDERS

A TYPE TS

B TYPE TSC

Capacity : 5 100 tons

Stroke : 50 200mm How to understand Model No.
Maximum Pressure : 700kgf/cm2
Hydraulic Coupler : 3/8 PT TS-55
Pump : To use 30% more than oil capacity
of Cylinder Stroke, 50mm
Capacity, 5ton
Single-Acting
Specifications TECPOS

Cylinder Retracted Extended Cylinder Cylinder Piston Base to

Cylinder Oil
Stroke Effective Height Height Out Dia. Bore Dia. Rod Dia. Inlet port Weight
Model Capacity Capacity
(mm) Area (kgs)
(tons) (cc)
(cm2) A B C D E F
TS-55 50 35 134 184 1.1
TS-510 100 70 184 284 1.4
5 6.38 38 28.5 25 25
TS-515 150 106 234 384 1.8
TS-520 200 140 284 484 2.2
TS-105 50 76 133 183 2.1
TS-1010 100 152 183 283 3.4
10 15.2 58 44 38 20
TS-1015 150 228 233 383 4.8
TS-1020 200 304 283 483 5.6
TS-205 50 166 165 215 7
TS-2010 100 332 215 315 8.8
20 33.18 88 65 57 35
TS-2015 150 498 265 415 11
TS-2020 200 664 315 515 12.7
TS-305 50 220 172 222 9.8
TS-3010 100 440 222 322 12.5
30 44.18 102 75 65 35
TS-3015 150 660 272 422 16
TS-3020 200 880 322 522 17.5
TS-505 50 355 173 223 15.8
TS-5010 100 710 223 323 20
50 70.88 127 95 85 35
TS-5015 150 1070 273 423 23.5
TS-5020 200 1425 323 523 27.7
TS-10010 100 1330 226 326 34
100 132.7 168 130 110 40
TS-10015 150 1991 286 436 44.5
The above options are subject to change without prior notice

4
 100

HYDRAULIC HAND PUMPS

THP-1A THPA-1B THPA-1C

THP-2B THP-3A THP-3B

THP-3A-D THP-28

Reservoir Capacity : 280-10000cc

Volume per stroke : 1 7 cc/stroke
Maximum Pressure : 700 kgf/cm2
To order double acting hand pump add the letter
“D” to the model No. ex) THP-3A-D

Specifications

Reservoir Volum per stroke (cc) Piston Dia. (mm) Piston Weight The auality of Working
Model
Capacity (cc) High Pressure Low Pressure High Pressure Low Pressure stroke(mm) (kgs) the material Pressure(kgf/cm2)
THP-1A 280 1.0 5.0 10 10 14.5 4

THPA-1B 800 2.0 13.0 11 28 4 ALUMINUM

THPA-1C 1600 2.0 16.5 11 32 8 ALUMINUM

20.5 700
THP-2B 2300 2.3 31 12 44 10.5

THP-3A 3000 2.3 31 12 44 12.5

THP-3B 10000 4.7 85 14 60 30 50

THP-28 1500 0.5 11.7 5.5 28 19 6.1 ALUMINUM 2800

The above options are subject to change without prior notice

20
 101

THP-1A THP-3A

THPA-1B

THPA-1C THP-3B

THP-2B THP-28

Hand Pump Hydraulic Hose

Maximum Pressure：700 kgf/cm2 Maximum Pressure：700∼2500 kgf/cm2
Oil Capacity：To use 30% more than cylinder oil Shorter length recommended
Standard length 1.8m (700kgf/cm2)

Hydraulic Oil Pressure Gauge

Oil Density： Dia Size：64mm & 1000kgf/cm2
–Warm Area：#40 100mm & 1000kgf/cm2
–Cold Area：#32 100mm & 2500kgf/cm2
-HAND Pump Area : #15

The above options are subject to change without prior notice

21
 102

INSTRUCTION
FOR
ELEC.-HYD. DECK MACHINERY

FLUTEK, LTD
 103

MOD.
NO. DATE SIGN DETAILS OF REVISION CAUSE OF REVISION
1
2
3

CHECKING OF RADIAL ALLOWANCE BY LEVEL GAUGE AT

INTERVALS OF 90°.

THE FOUNDATION OF WINCH TO BE LEVELED AS CAREFULLY AS

POSSIBLE, MAX DEVIATION FROM HORIZONTAL 1.0mm / 1000mm

MAX ALLOWED DIFFERENCE A = 0.2mm AT

CENTER LINE OF THE CLUTCH

CHECK ALL
4 POINTS

CABLE
MOORING
LIFTER
DRUM
PART
PART

NOTE!! BEFORE MEASURING THE CLUTCH OF

MAIN SHAFT HAVE TO BE GREASED WELL.

TITLE ELEC.-HYD. DECK MACHINERY

SCALE UNIT
N
S MM

JHP
FMW45-0492B
A4 (210X297)
 104

Guidance on Usage of a Double-nut

Engineering Section
Marine Equipment Department
Kawasaki Precision Machinery Ltd.

Below, guidance on usage of a double-nut for installation of our winch is given. This document is
just guidance, so in actual work, influence due to the bolt material, shape, conditions of the installed
portion, etc. must be taken into account.

● Combination of nuts
The tightening force of a double-nut is determined by the strength of the upper nut, so “a
normal height nut” is located above, and “a thin nut” is located below in general. (In case a thin
nut is not applicable, the double-nut can consist of the upper and lower nuts of the same height.)

● Tightening procedure of a double-nut

① Tighten the lower nut at 90 % of the rated torque.
② Fix the lower nut with a tool like a spanner, and tighten the upper nut at 110 % of the rated
torque.
③ Fix the upper nut with a tool like a spanner, and rotate the lower nut in the loosening direction
until torque abruptly rises after torque of a constant value.

Note 1: In case the upper nut is thin (a thin nut), the upper nut is overcome by the axial force of the
bolt, and can break.

Note 2: Anti-loosening effect cannot be obtained by tightening the upper nut only after tightening
the lower nut. So, be sure to rewind the lower nut in the loosening direction.

Note 3: Be sure to tighten the nuts at the torque respectively specified above. Too large or too
small tightening torque can cause breakage or loosening of the bolt and nuts.

② Tighten the upper ③ Loosen the lower

① Tighten the lower nut (thin nut) until
nut (thin nut) at 90 % nut (normal height
nut) at 110 ％ of the torque changes.
of the rated torque.
rated torque.
Normal
height nut
Normal
Height
nut

Bolt axial force

is received by
the upper nut
Thin nut only.
Thin nut Thin nut

Tightening force of Anti-loosening effect

the lower nut is lost is generated by
by tightening the occurrence of
upper nut. mutually pushing
force of the upper nut
and the lower nut.
 105

INSTRUCTIONS MANUAL

(3) Connect the shackles to the clearance

LIFTING GUIDANCE – PUMP UNITS holes in the eye plates. (Four places).

1. Required equipment (See Fig.2-1, 2-2, 2-3)

Lifting arrangement with a capacity, including

safety, of minimum the weight of the equipment.
The eye plate for lifting is mounted to a bed.
(Fig.1) The size of eye plate same as to all unit.

<Fig.2-1 Above>

<Fig.2-2 Front>
Fig.1 Detail of eye plate mounted to a bed

2. Preparation
Please you hoist the Pump unit as follow

(1) Ensure that bolts of shackle are sufficiently

tightened.

(2) Balance the Power Pack with the lifting

equipment.
(Example with 2 pumps) <Fig.2-3 Side>

1/2
 106

INSTRUCTIONS MANUAL

(4) Check the slings and Pump unit 4. Important to notice

components for any interference that may
cause damages. The system contains hydraulic oil. Oil leakage
could cause pollution to the environment.
(5) Provide for a safety zone along the The lifting bolts connected to the Elec. Motor
intended transportation track. body are not designed for lifting the entire
Pump unit, but only for dismantling the Elec.
3. Line of actions Motor from the Pump unit.
Incorrect use may cause substantial damage
(1) Lift the Pump unit carefully just above to the Pump unit.
ground level and check for complications. Remember to put safety first.

- If the Pump unit slanting to one of the sides,

use a stabilizing attachment.

- If the wire badly influence the equipment, try

to clear the path of the wire. If any complication
should appear, do not try to continue the hoist,
but lower the Pump unit again. Try to solve the
problem before you continue.

(2) Pay attention to the safety zone as well as

the Pump unit itself. Not under any
circumstances should a person stay beneath
the Pump unit under the transportation or
under the lifting process.

(3) During transportation, keep the Pump unit

as close to the ground as possible, avoiding
collisions with any surrounding objects.

(4) As the Pump unit has been brought above

it’s destination, slowly lower the Pump unit and
secure it in an upright position.

2/2
 107

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
 108

INSTRUCTIONS MANUAL

LIFTING GUIDANCE – Mooring winch (Two drum)

1. Preparation and line of action

- 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 wire has sufficient strength to carry the winch.
- The weight can be found in the weight specification on each package.
- 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.
- Remember always to put safety first.

3/3
 109

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.
 INSTRUCTIONS MANUAL

CHAPTER 3.

INSTRUCTION FOR OPERATION

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OPERATION NOTES

Any of the phenomenon shown below is normal, not an error.

PHENOMENON
During the use of the chain drum, the chain is gradually paid out even if
the control valve handle is kept at the stop position.

Reason
With a load on the hyd. Motor, it leaks internally a very small amount of hyd.
Fluid. During the use of the chain drum, the hyd. Motor is subjected to the self
weight of the anchor and chain, so that a small amount of flows through the hyd.
Motor, which results in the paying-out of the chain. In case of 2-speed valve is
used, the valve position kept at the low position.

Notes
The chain speed may be max. 700 to 800 mm/min.*depending on the length of
the chain already paid out. This speed is within a normal range.
Immediately after use, tighten the brake.

Even if the paying out speed exceeds this value, it is not error in all cases. In
case of exceeding this value, we confirm whether it is error or not by calculation
in each case.

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PHENOMENON
During the sea trial, normally three cable lengths are paid out for each of the port
and starboard sides, and then the lifting speed is measured separately for each
of the port and starboard side anchors. The lifting speed may be different
between the port and starboard side anchors.

Reason
We adopt variable displacement type as a motor, and we mount a regulator by
which lifting speed is varied according to load automatically in hyd. Motor. Then
variations in load (anchor and chain weight, hose pipe efficiency, winch’s
mechanical efficiency and hyd. Motor’s mechanical efficiency) may cause the
lifting speed to differ between the port and starboard sides. And variation in the
setting of components as well, may cause the lifting speed to differ.
Many factors, including those mentioned above, affect the lifting speed
separately for each of the port and starboard side chain and anchor hoisting
system. Then the lifting speed differs from each other.

Notes
The rule requires each pair of chain and anchor to be lifted at a speed at least 9
m/min. on condition that only the port or starboard side windlass is in operation.
Difference of chain hoisting speed between port and starboard side is not a
problem, when each hoisting speed satisfies specifications. (The difference of
hoisting speed is not a classification matter.)

Many cases of different hoisting speed for each of the port and starboard
windlass, including those with a difference in lifting speed between port and
starboard sides by as large as 15 to 20%, have been reported.

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PHENOMENON
During a initial stage of use, the pawls of the chain drum are deformed.

Reason
New pawls have a very small pawl-to-chain contact area so that the pressures
acting on the pawls become very large, and exceed far over the yield point of
the material, which results in the deformation of the pawl.

Notes
With use, the contact area becomes larger gradually, so that the pressures
become smaller. When they become smaller than the yield point of the material,
no further deformation will occur.
Our company has experienced delivery of thousands of windlasses. However, we
haven’t received any trouble reports stating that the wear (deformation) of the
pawl interferes with the normal use of the chain drum.

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PHENOMENON
The work of the hyd. Pumps differs each other.
(If the hyd. Circuit is ring main circuit.)

Reason
The total work of N sets of hyd. Pumps is automatically adjusted depending on
the required flow. The work of each pump is independently adjusted by the
regulator separately mounted to each of the pumps, so that the work may differ
among the pumps.

Notes
The pump unit of this ship is designed so that the total power produced by N
sets of pumps can satisfy the specified power requirement. Therefore, whether
or not the work of each pump differs is not a matter.
If the power requirement is equal to or smaller than the capacity of one pump,
only one pump may be engaged while other pumps are at rest.

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Operation of windlass

1) If the chain should be wound under the condition of high tension in

stormy weather, tension should become too high
in a moment by rolling of the vessel and large load should work
on the windlass.
In storm weather wind the chain while advancing the vessel slowly and
loosening the chain fully.

2) In case that the anchor clings to the anchor chain in winding

operation, never try to release the anchor from the anchor chain in
the air, and carry out the following procedure.

① Immediately apply the brake.

② Take off the clutch in order to separate the chain wheel from the drive system.
③ Loosen the brake slowly and lower the anchor to near the bottom of the sea.
④ Release the brake. (Let the anchor fall to the bottom of the sea and the
anchor will be released by the impact.)
⑤ Apply the brake and put on the clutch in order to connect the chain wheel to
the drive system.
⑥ Wind the anchor with the hydraulic drive system.

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Oil charging and Air expelling

1) Fill the tank with oil.

2) Ensure that each valve is in its normal position. *1
3) Ensure that the levers of control valves are in their neutral position.
4) Fill the hydraulic motors and pumps with oil.
5) Start up an electric motor and run one (1) pump.
6) Open the stop valve no. 70.
7) Open the air vent valves (hyd. Motors, counterbalance valves, strainers, oil
coolers, and control valves) and expel air in the circuit.
8) After air expelling, and oil level in the tank became constant, stop the hyd.
pump.
9) Add oil in the oil tank.
10) Start up an electric motor and run one (1) pump.
11) After oil level in the tank became constant, stop the hyd. pump.
12) Close the stop valve no.70.
13) Add oil in the oil tank.
14) Expel air from the control valves
15) After completing air expelling, return levers of control valves in their neutral
position.
16) Run the hydraulic motors with no load. (Clutch to be on and brake to be
released.)
17) When there is no air in return oil, air expelling to be finished.
18) Add oil in the oil tank.

*1 : Refer to page 3 “HYD. CIRCUIT DIAGRAM”

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CAUTION FOR INSTRUCTION

Whenever any pump unit opening and/or inspection work is required to carry out,
Fill sufficient amount oil into the drain piping and air bleed piping arrangement
without fail prior to re-start running.

Preliminary Operation

VALVE 1) Each valve to be in its normal position.

2) The lever of control valve to be in its neutral position.
WINDLASS 1) Brake, Bearing : Grease up bearing metals and linkages.
MOORING WINCH (Refer to the notice place in chapter 4.)
2) Gear
a) In case of Open gear : Apply gear oil.
(Refer to the notice place in chapter 4.)
“ MAINTENANCE FOR THE GEAR ”
b) In case of Enclosed gear : Confirm that the level of
lubrication oil is in proper range of oil level gauge.
OIL TANK 1) Oil level in tank.

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Starting and warming up operation for

the hydraulic pumps
(Refer to next page “ VISCOSITY-TEMPERATURE GRAPH OF HYDRAULIC OIL “ )

Oil viscosity Procedure

[Starting – Warming up]
1. Fully open the stop valve 70.
2. Start only one hyd. pump.
3. Fully close the stop valve 70 when oil
viscosity becomes below 500 cSt.

Note:
If it takes long time to warm up, close partly the stop valve
500 ~ 2000 cSt
70 and raise delivery pressure to about 5.0 Mpa

Caution:
When environmental temperature is low (below about -10°
C) and oil in piping is likely to become over 2000 cSt,
start warming up according to above procedure and keep
viscosity of oil in piping below 2000cSt without reference
to oil temperature in tank.
1. Check the direction of rotation by inching then start the
Below 500 cSt hyd. Pumps.
2. Start the hyd. Pump.

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Operation of windlass and mooring winch

Note : When driving the windlass, set the stopper for lever of control valve.

(Refer to “Stopper for lever of control valve for windlass“ )

1) Stopper of control valve to be off.

2) Clutch to be on and to insert the pin and fix the clutch lever.
3) Procedure
Lever of control valve Note (Refer to next page)
STOP In “STOP” position Refer to Fig. 1
Refer to Fig. 2
UP(WIND) In “UP” (“WIND”) position
Refer to Fig. 3
Refer to Fig. 4
DOWN(SLACK) In “DOWN” (“SLACK”) position
Refer to Fig. 5
4) After operating, lever of control valve to be in its neutral position and brake to
be put on and clutch to be off.
5) Stopper of control valve to be on.
6) Operation of the windlass in bad weather.

Operate the windlass carefully not to apply excessive external force to

the chain when using it in bad weather.

Stop operation of Hyd. Pump

1) Ensure that the lever of control valve is neutral position.

2) Ensure that brake to be put on.
3) Stop the electric motor for hyd. Pump.

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 INSTRUCTIONS MANUAL

Safety Device

As safety devices following interlocks are provided.

When the hydraulic pump is unable to start or stops during operation or if any of
them has been interrupted during servicing, check to see if such interlocking
equipment and/or devices are being energized or not.

1) Thermal switch (installed on the oil tank) :

When the temperature of hydraulic fluid shows “ HIGH “, the electric motor
for Hyd. Pump trips. (Setting temperature : 75℃)

2) Float switch (installed on the oil tank) :

When the liquid level of hydraulic fluid shows “ LOW “, the electric motor for
of Hyd. pump trips.

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 INSTRUCTIONS MANUAL

Cautions

Operation of winch
1) Rope winding direction :
Make sure that the winding direction of hawser (or wire) drum, and of warping
end are being specified strictly.
Therefore, you will please wind the rope in the specified direction correctly.
If carelessly rope has been wound reversely, you can hold loading in the
position of handle “ STOP “, as well as you can not make speed control at
wind feeding. This might result in a dangerous state.

Caution to be taken while hyd. pump is running

While the hyd. pump is running, pay special attentions to the below items :

1) Pump discharge pressure

Check to see if the pump discharge pressure is within the specified pressure
valves.

2) Low-pressure valve
While the hyd. pump is running, never close the valves provided in the
low-pressure section (return line and drain line *)
(If not, valves, etc. might be broken.)
* If the hyd. circuit is “ drain line less “ system, there is no drain line.

3) Working oil temperature

When the temperature of working oil rises up to more than 65℃, stop the
operation.

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 INSTRUCTIONS MANUAL

4) Oil leak from each equipment

If any oil leak is caused, stop the hyd. pump and repair the equipment.

5) Abnormal noise and abnormal vibration.

Upon finding any of there, stop the operation directly and apply proper
treatment. Reference is to be made to Chapter 4 Trouble shooting list.

6) Blockade of the strainer

① Strainer for the return line and drain line. *
If the indicator indicates “YELLOW“ change the element.
② Strainer for the suction line.
If the indicator indicates “YELLOW“ clean the element.

* If the hyd. circuit is “drain line less“ system, there is no drain line.

7) Oil cooler

In low temperature, close the globe valves and remove the sea water from
the oil cooler.

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 INSTRUCTIONS MANUAL

Adjustment of the hydraulic equipment

The hydraulic equipment do not require any adjustment to be performed on the

ship as it has been adjusted at the work.
If any disorder occurs on the hydraulic equipment, consult us directly according
to its contents, FLUTEK will advise you the adjusting procedure in detail or
dispatch responsible engineers.

Stopper for` lever of control valve for

windlass

The local control valve for windlass is equipped with a stopper on the control
lever for operation of windlass and mooring winch.
Stopper shall be set as shown below.

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 INSTRUCTIONS MANUAL

CHAPTER 4.

MAINTENANCE AND CHECKING

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 INSTRUCTIONS MANUAL

MAINTENANCE MANUAL (DIGEST)

Prior to operation In operation After operation Notice

a. The lever of a. To be no oil a. The lever of a. Change the

control valve to leakage. control valve element of strainer
be in its neutral If no leak, to be in its if the indicator
position continue to neutral indicates
operate. position. “YELLOW”.

If oil leakage,

1) Put on the
brake.
2) Stop the pump.
3) Repair the pipe
joint.

b. Each valve to b. Oil temperature b. Each valve to b. Clean the filter the
be in its normal to be less than be in its counterbalance
position. 65℃. normal valve every two
Otherwise position. hundred hours. Pull
hydraulic fluid out the plug taken
might splash out easily.
from the piping,

See “Hyd.
Circuit
Diagram”.

c. Check the oil c. Put on the c. Operation of the

level in the gear brake. windlass in bad
box of weather. Operate

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 INSTRUCTIONS MANUAL

windlass and the windlass

winches. carefully not to
apply excessive
external force to
the chain when
using it in bad
weather.

d. Grease up d. Periodically(at
bearing least monthly)
metal and check the zinc
linkages. corrosion bars on
oil cooler and if the
remained volume
becomes 40% or
less of original
size.
Exchange with new
one.

e. Oil level in tank.

(if not, fill the
Tank with oil.)

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 INSTRUCTIONS MANUAL

MAINTENANCE FOR THE GEAR

Supply lubricant (gear compound) on the gear teeth prior to running the winch.

GEAR
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.

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 INSTRUCTIONS MANUAL

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
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.

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 INSTRUCTIONS MANUAL

Therefore, such water-mixed/contaminated hydraulic fluid must be changed

with fresh hydraulic fluid.

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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 NOTE
1. Grease point shown in this drawing
is for our standard Windlass
2. Please apply grease all the linkages and
the points that grease nipple is equipped.

MARK INTERVAL LUBRCANT

EVERY WEEK &

GREASE
BEFORE & AFTER OPERATION

EVERY MONTH &

GEAR COMPOUND
BEFORE OPERATION

APPLY THE GREASE ON SCREW SECTION BY BRUSH

NO. PART NO. PART NAME MAT'L Q'TY DIMENSION REMARKS

TYPE ELEC.-HYD. DECK MACHINERY

SCALE UNIT
S
N MM

KHP
12.02.13
111

A3 (297X420)
112
 INSTRUCTIONS MANUAL

Windlass, Winch, Hydraulic Motor,

Control Valve and Piping Materials

The applicable checking and maintenance program is as shown below :

Where, C : Check
O : Overhaul
Maintenance & Checking Period
Code Maintenance & Checking Locations Prior to Every 3 As
Operation Months Required
1 Check condition of corrosion on C
Applicable parts.

2 Check oil leak from parts. C

3 Check conditions of lubrication of C

Applicable parts.

4 Check abrasive conditions of brake C

lining.

5 Replacement of brake lining. O

6 Check hydraulic motor noise. C

7 Overhaul of hydraulic motor. O

8 Check lubrication oil for open gear. C

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 INSTRUCTIONS MANUAL

Pump Unit and Filter

The applicable checking and maintenance program is as shown below :

Where, C : Check
O : Overhaul
Maintenance & Checking Period
Code Maintenance & Checking Locations Prior to Every 3 As
Operation Months Required
1 Check hydraulic pump noise. C

2 Overhaul of pump unit. O

3 Check oil level in oil tank. C

※4 Check deterioration of hydraulic fluid. C

※5 Change hydraulic fluid with fresh fluid. O

6 Check indicators of drain filter and return C

filter.*

7 Replacement of filter element of filter O

Asterisk (※) shows that the item should refer to Section 3-1 above.
*If the hyd. circuit is “drain line less” system, there is no drain line.

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 INSTRUCTIONS MANUAL

Oil Cooler

When the oil cooler is being equipped, pay special attention to the below point.
1) If the cooling water might be frozen, drain off water from the oil cooler.
2) Periodically overhaul the bonnet every six months, and check on the abrasive
start of the protective zinc bars.
3) In order to prevent the oil cooler from the decrease of a cooling
performance, periodically clean the cooling surfaces of the oil cooler thoroughly.

Others

Hydraulic motor

Open the drain port provided in the bottom section of the hydraulic motor for
every 200 hours.

Then remove contaminated oil and impurities from the inner parts of the hydraulic
Motor thoroughly.

After restoration, fill up the inside hydraulic motor with fresh hydraulic fluid.

Oil leakage

Be careful that oil-leakage would result in a serious accident.

Therefore, if any oil-leakage has been found, immediately check the cause of
troubles, and repair the defective parts.

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 INSTRUCTIONS MANUAL

Overhauling and adjustment of oil-hydraulic equipment

Since the oil-hydraulic equipment are being checked and adjusted before the
delivery from the manufacturer’s shop, the oil-hydraulic equipment is so designed
as to be free from further adjustment.

If any malfunction has occurred on the oil-hydraulic equipment, and any

overhauling and adjustment are required to carry out, immediately contact with us.

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.

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 INSTRUCTIONS MANUAL

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) (mm)
Ø (mm)
Chain Drum 84 1700 12.5 4.5 8
Hawser(Wire) 1400 8 2 6
Drum

The brake lining becomes accessible from the opposite side of the drum flange
and you can measure the thickness of the lining by loosening the brake support
and brake. Measure the thickness at regular intervals so that the brake lining can
be replaced before it is worn out excessively.

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 INSTRUCTIONS MANUAL

Remark

<For mooring winch>

<For windlass>

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 INSTRUCTIONS MANUAL

Maintenance on failure of hydraulic

winch
Each control valve is equipped with stop valves as shown on the next pages.
Disconnect the hydraulic winch from the main line according to the following
procedure.

1) Remove the plug (Item No. 5)

2) Loosen the set screw (Item No. 4)
3) Tighten the puppet (Item No. 2)

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INSTRUCTIONS MANUAL

CHAPTER 5.

TROUBLE SHOOTING LIST

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 INSTRUCTIONS MANUAL

TROUBLE SHOOTING LIST

Event of Trouble Causes Measures

Load can not be hoisted. 1. Winches are used 1. Check the condition
over delivery of hyd. pumps. of simultaneous operation.

2. The regulator of hyd. pump 2. Re-adjust the regulator and

is out of order. set correctly.

3. The relief valve in the pump 3. Re-adjust the relief valve

unit is out of order. and set correctly.

4. The relief valve for counter 4. Re-adjust the relief valve

balance valve is out of and set correctly.
order.

5. Excessive leakage of oil. 5. Check the pump,

the motor, the valve and
the pipe joint.

6. Air contained in the oil. 6. Expel air in the circuit.

External oil leakage of the 1. Excessive wear of damage 1. Dismantle the front cover
hydraulic pump. of the oil seal packing. and replace the oil seal
packing.

2. Loose of the bolts. 2. Tighten the bolts hard up.

Abnormal state of 1. Abrasion of the spring in the 1. Replace the spring with a
the hydraulic motor. counterbalance valve. new one.

2. Throttling of the spool of 2. Clean with compressed air.

the counterbalance valve
clogged.

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 INSTRUCTIONS MANUAL

3. Filter in the counterbalance 3. Clean with compressed air.

valve is clogged.
Abnormal noise is audible 1. Air mingling into circuit. 1. Thoroughly practice
air expelling from the
circuit.

2. Excessive high viscosity of 2. See Chapter 2-2

working oil.
Electric motor 1. Oil level in tank. 1. Fill the tank with oil.
stop because of the float
switch activated. 2. Oil leak from piping 2. Check piping
and equipments. and equipments.

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 INSTRUCTIONS MANUAL

CHAPTER 6.

DETAIL DESCRIPTION OF MAIN PARTS

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 INSTRUCTIONS MANUAL

6-1. HYD. MOTOR (TYPE : HMKB,

HMKC, HMC)

CONSTRUCTION

OPERATION AND PRINCIPLE

DISASSEMBLING AND REASSEMBLING

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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
Overhaul & Maintenance manual.

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.

STAFFA PAGE 3 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

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

STAFFA PAGE 4 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

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

STAFFA PAGE 53 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

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.

STAFFA PAGE 6 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

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.

STAFFA PAGE 7 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

Hydraulic Motor
Fault Possible Causes Remedy
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.

STAFFA PAGE 8 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

Hydraulic Motor
Fault Possible Causes Remedy
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

STAFFA PAGE 9 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual

(7) DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 27 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual

DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 28 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual

DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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

STAFFA PAGE 29 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual

DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 30 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual

DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 31 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 32 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

DISASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 33 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 34 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

Once the drum is located on the shaft, the spacer plates

(if fitted) should be located.

Check the cones are fully seated by tapping them with a 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.

STAFFA PAGE 35 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 36 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 37 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 38 DATA SHEET

MOTOR OHM-1001-2/07.01
Overhaul & Maintenance manual.

ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 39 DATA SHEET

MOTOR OHM-1001-2/07.01
 ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 40 DATA SHEET

MOTOR OHM-1001-2/07.01
 ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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

STAFFA PAGE 41 DATA SHEET

MOTOR OHM-1001-2/07.01
 ASSEMBLY OF ‘C’ TYPE 7* SERIES MOTOR.

No. PROCEDURE CAUTION

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.

STAFFA PAGE 42 DATA SHEET

MOTOR OHM-1001-2/07.01
 ASSEMBLY FOR ‘C’ TYPE 7* SERIES MOTOR

No. PROCEDURE CAUTION

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.

STAFFA PAGE 43 DATA SHEET

MOTOR OHM-1001-2/07.01
ILLUSTRATED PARTS CATALOGUE

C270

STAFFA MOTOR
C270
SERIES 70
419 103 456

417

402
201: 4 = Q 201: 4 = S,Q
213

9=X
456

9 = C,CS,C1,C2
410

208
Views on Arrow "A"
305: 4 = P
452 209

471
303
484

205

212 101
255 205
453
210 454
211
401
208

206

203

401
202
404
414
426
105
420 435
408

404
476

415

"A" 474

415
102
475
305

109
102
482

497

479 418

413
422

301

405
418
Nameplate
104 or 153

PAGE 67
Staffa
Spare parts listing - High torque low speed motors

C270,70

CODE DESCRIPTION QUANTITY PART No.

101 Motor Case 1 25766

102 Valve Housing
- "F4" with "C" or "X" control ports 1 102-032
- "F4" with "CS" control ports 1 75272
- "FM4" with "C" or "X" control ports 1 102-033
- "FM4" with "CS" control ports 1 102-036
- "SO4" with "C" or "X" control ports 1 102-038
103 Front Cover 1 103-039
104 Valve End Cap
- "F4" & "FM4" ports 1 24867
- "SO4" ports 1 24867
105 Cylinder Head 7 26042
109 Spacer
- "X" Displacement Control 1 109-006
- "C" Displacement Control 1 109-005
- "CS" Displacement Control 1 109-005
- "C1" Displacement Control 1 109-005
- "C2" Displacement Control 1 109-005
153 Shuttle End Cap ( "CS" , "C1" & "C2" )
- "F4" & "FM4" ports 1 75989
201 Two Speed Crankshaft
30 Design :-
- "S" shaft 1 75264
- "P" shaft 1 75751
- "Z" shaft 1 75262
31 & 70 zDesign ( Low Noise ) :-
- "S" shaft 1 75571
- "P" shaft 1 76176
- "Z" shaft 1 75811
- "Q" shaft 1 76177
202 Piston 7 25032
203 Connecting Rod 7 25903
204 Piston Retaining Half Ring 14 24961
205 Con Rod Retaining Ring 2 24364
206 Restrictor Screw 7 25973
208 Displacement Drum
- for "P" , "S" & "Z" shafts 1 26170
- for "Q" shafts 1 26712
209 Large Displacement Piston
- 200 cubic inch Displacement 1 27159
- 220 cubic inch Displacement 1 25611
- 250 cubic inch Displacement 1 25610
- 280 cubic inch Displacement 1 25564
Standard seal kit Series 30 1 74576
Standard seall kit Series 70 & 31 1 76786
Page 68
Staffa
Spare parts listing - High torque low speed motors

C270,70

CODE DESCRIPTION QUANTITY PART No.

210 Small Displacement Piston

30 Design :-
- 10 cubic inch Displacement 1 26977
- 40 cubic inch Displacement 1 26225
- 60 cubic inch Displacement 1 26979
- 80 cubic inch Displacement 1 25614
- 100 cubic inch Displacement 1 26334
- 120 cubic inch Displacement 1 27259
- 140 cubic inch Displacement 1 25612
- 160 cubic inch Displacement 1 26361
31 & 70 Design ( Low Noise ) :-
- 10 cubic inch Displacement 1 27111
- 40 cubic inch Displacement 1 27112
- 60 cubic inch Displacement 1 27123
- 80 cubic inch Displacement 1 26972
- 100 cubic inch Displacement 1 27115
- 120 cubic inch Displacement 1 27117
- 140 cubic inch Displacement 1 27119
- 160 cubic inch Displacement 1 27120
- 180 cubic inch Displacement 1 27293
- 200 cubic inch Displacement 1 27126
211 Rear Bearing Spacer Plate 1 25793
212 Large Spring for Displacement Piston 1 66111
254 Front Bearing Spacer Plate 1 25793
301 Valve Spool
- "F4" & "FM4" ports 1 26195
- "SO4" ports 1 25704
303 Oldham Coupling 1 27659
305 Shim Kits 1 77393
401 Rear Bearing 1 89668
402 Front Bearing 1 89668
404 Piston Seal Ring 7 25946
405 Valve Seal Ring
- "F4" & "FM4" ports 12 27477
- "SO4" ports 12
408 Circlip (Piston Internal) 7 87551
410 "O" Ring (Front Cover)
- Standard Seals 1 63167
413 "O" Ring (Valve End Cap)
- "F4" & "FM4" ports - Standard Seals 1 67950
- "SO4" ports - Standard Seals 1
Page 69
Staffa
Spare parts listing - High torque low speed motors

C270,70

CODE DESCRIPTION QUANTITY PART No.

414 "O" Ring (Cylinder End Cap)
- Standard Seals 7 81449
415 "O" Ring (Internal Ports)
- Standard Seals 7 67270
416 "O" Ring (Spacer Internal Ports)
- Standard Seals 7 67270
417 Shaft Seal 1 60675
418 S.H.C.S. (Valve Housing / Spacer / Motorcase)
- "F4" & "FM4" ports 7 84599
- "SO4" ports 7 84599
419 S.H.C.S (Front Cover) 7 63021
420 S.H.C.S.(Cylinder Head Cap) 70 84577
422 S.H.C.S. (Valve End Cap)
- "F4" & "FM4" ports 5 84527
- "SO4" ports 5 84527
426 Bonded Seal, Drain
- Standard Seals 2 81249
435 Drain Plug 2 63191
452 Small Piston Seal Ring
- 30 Design 1 25463
- 31 Design ( Low Noise ) 1 26533
453 Large Piston Seal Ring 1 25568
454 Shaft Seal Ring 6 26099
456 Steel Plug (Spacer) 2 67171
471 Shaft Seal Backing Ring 1 26100
474 "O" Ring (External Ports)
- Standard Seals 2 80849
475 "O" Ring (Spacer Surround)
- Standard Seals 1 65374
476 Back-Up Ring (Cylinder End Cap)
- Standard Seals 7 66585
479 Steel Plug (Valve Housing)
- for "F3" & "F4" ports 2 67117
- for "FM3" & "FM4" ports 2 67171
482 "O" Ring (Valve Housing Surround)
- Standard Seals 1 65374
483 Piston Seal Backing Ring 1 24556
497 "O" Ring (Spacer Pressure Feed)
- Standard Seals 1 67296
758 Shuttle 1 67293
764 "O" Ring (Shuttle End Cap)
- Standard Seals 1 67296
765 Shuttle Stop Plug 1 26205
766 Bonded Washer (Shuttle Stop Plug) 1 67386
PAGE 70
 INSTRUCTIONS MANUAL

6-2. KAWSAKI SWASH-PLATE TYPE

AXIAL PISTON PUMP

COPYRIGHT FLUTEK, LTD

Attached dwg. 1
 KAWASAKI SWASH PLATE TYPE
AXIAL PISTON PUMP

K3VL series

MAINTENANCE MANUAL

COPY JOB No.

Revisons KAWASAKI HEAVY INDUSTRIES, LTD.

PRECISION MACHINERY COMPANY
ENGINEERING DIVISION
COMPONENTS ENGINEERIGN DEP. 1
APPROVED. N. Okamoto

CHECKED. K. Matsuda

DRAWN. I. Yoshimura

DUP. 1 DATE OCT. 2, 2001 Drawing No.

SUM. FILING No. 03890344A
（ 17 SHEETS INCLUDING COVER）
 1
Contents

1 Disassembly and Assembly of the Pump 2

1-1 Tools 2
1-2 Procedure of Disassembly 3
1-3 Procedure of Assembly 8
Attached Drawing No.1 Exploded Drawing 13

2 Judging Standard for Maintenance 14

2-1 Judging Standard for replacing worn parts 14
2-2 Judging Standard of cylinder, valve plate, swash plate, and
shoe plate 15
 2
1 Disassembly and Assembly of the Pump
1-1 Tools
The following tables show tools required when disassembling and
assembling K3VL pumps.

Mark ○ means that the

Tool name and size tool is required. Part name
Size of the pump
Hexagon
B Hexagon Plug
socket
Name Width 140 socket (ROH type) Others
head set
(mm) head bolt
screw
4 ○ M8 NPTF 1/16 plug
5 ○ M6 G 1/8 M10
6 ○ M8 G 1/4 M12,M14
8 ― M10 G 3/8 M16,M18
Allen wrench
10 ○ M12 G 1/2 M20
12 ○ M14 G 3/4
14 ○ M16,M18 Servo piston
17 ○ M20,M22

B Plug
Plug
Name Width 140 Nut (ISO thread)
(UNF thread)
(mm)
―
22 △ ― 3/4 UNF
Double ring ―
spanner, 24 □ M16 M14×1.5
Socket wrench,
30 ― ― M22×1.5
Spanner
32 ○ M20 1-1/16 UNF ―
36 □ ― ― M27×2
14.3 ○ ― 7/16 UNF ―
Adjustable
single ○ Medium size, 1 piece
wrench
Screw driver ○ Medium size, 2 pieces
Hammer ○ Plastic hammer, 1piece
○ Pliers for snap ring(see below)
Pliers
― Pliers for retaining ring(see below)
Torque
○ Capable of tightening with specified torque
wrench
Mark stands for “ required for SAE mounting type.”
Mark stands for “ required for ISO mounting type.”
Mark ― stands for “ not required”

Plier for snap ring Plier for retaining ring

 3
1-2 Procedure of Disassembly

Before disassembling, read all pages of this disassembly section.

When disassembling, follow the order of procedures written in the next table.
Numbers in the parentheses next to the part name shows the part number in
the following drawings:
Attached Drawing No.1 Exploded Drawing
Attached Drawing No.2 K3VL140/B Cross Section
 4
Notes
№ Work
Select an appropriate place to (1) The place must be clean.
1 disassemble. (2) Spread rubber sheet, cloth, etc. to
prevent parts from being damaged.
Remove dust, rust, and so on from the
2
surface of the pump with cleaning oil.
Remove the drain plug (467) and drain (1) Drain off as much oil as possible.
3 off hydraulic oil out of pump casing
(271).
Remove hexagon socket head bolts (411 (1) When disassembling the regulator,
in case of K3VL45, 80), (411 and 412 in refer to the manual of the regulator.
case of K3VL112, 140), and then remove (2) Be careful not to drop O-ring from
the regulator from the casing. the gasket surface of the regulator.
(3) Prevent dust from entering into the
regulator.

Loosen hexagon socket head bolt (401, (1) Remove the regulator before
402) tightening valve cover(312) and the loosening the bolts.
pump casing. (2) In case through drive kit is installed,
remove sub-plate adapter (317) and
coupling (116) beforehand.
(3) Oil will come out from between
pump casing (271) and valve cover
5 (312). Be careful and remove oil to
keep the place clean.
 5
№ Work Notes
Place the pump horizontally on (1) Pull out valve cover perpendicular to
workbench. Separate pump casing (271) the direction of the shaft. (In order to
from valve cover (312). prevent damage of the needle bearing
and the contacting surface of the
shaft.)
(2) Be careful not to damage the
contacting surfaces between valve
6 cover and pump casing.
(3) When removing valve cover, valve
plate comes out attached to valve
cover. But valve plate may easily
detach from valve cover and fall
down. Be careful not to damage valve
plate.

When necessary, remove needle bearing (1) Do not remove needle bearing unless
(124) and valve plate (313) from valve the bearing is considered to be near
cover(312). the end of its expected life.
7
(2) Dot not loosen nut (808). Delivery
flow rate will change when nut is
loosened.
Pull cylinder (141) out from pump (1) Be careful not to damage sliding
casing straight over drive shaft. Pull out surfaces of cylinder (141), spherical
pistons (151), set plate (153), spherical bush (156), shoe (152), piston (151),
bush(156), cylinder springs (157) at the and swash-plate (212).
same time. (2) Be careful not to damage surface of
the shaft contacting needle bearings.

8
 6
№ Work Notes
Remove retaining ring (406) in case of (1) In case of K3VL80, 112, 140, seal
K3VL45 or hexagon socket head bolts cover (261) is easily removed when
(406) in case of K3VL80, 112, 140. two bolts are inserted into holes (with
Remove seal cover (261). female thread).
(2) Be careful not to damage oil seal
(774) on seal cover (261).
(3) In case of spline shaft, cover spline
9 part with plastic tape so as not to
damage oil seal.
In case of key shaft, remove key
before seal cover is removed.

Tapping drive shaft (111) lightly on the (1) Hold front side of shaft when
end of valve cover side with a plastic tapping to prevent shaft from flying
hammer, extract drive shaft from pump out.
casing. (2) Tap shaft horizontally (in
accordance with shaft direction) not
to damage front roller bearing.
(3) As front roller bearing and shaft are
10 fit tightly (shrinkage fit), do not
remove front roller bearing unless it
is considered to be near the end of its
expected life.

Pushing down servo piston (532), (1) Be careful not to damage shoe plate,
remove shoe plate (211) and swash plate and the sliding round surface of swash
(212) from pump casing. plate.

11
 7

№ Work Notes
(1) Use both hands to lift up swash
Remove swash plate support (251) from
plate support (251) .
pump casing (271).

13

Only when necessary, remove servo (1) When removing servo piston, use a
piston (532), tilting pin (548), special jig not to damage head part of
outer/inner servo bias springs (535, tilting pin.
536), spring seat (537), and plug (538). (2) Adhesive (Three bond No.1305B) has
been applied on the connecting part
14
between tilting pin and servo piston.
Be careful not to damage servo piston.
(3) Be careful not to clamp fingers by
springs when removing tilting pin
from pump casing.
 8
1-3 Procedure of Assembly

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

Be careful of next items.

(1) Before assembling, make sure that all parts are prepared and all damaged parts
are fixed or replaced by new ones.
(2) Before assembling, wash each part with clean oil and dry it with compressed air.
Select an appropriate clean place to assemble. When dust enters, it may cause
trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces and bearings.
(4) Do not reuse O-ring, oil seal, and other seal parts.
Replace with new one.
(5) When assembling parts that easily detach, like an O-ring, apply clean grease to
prevent them from dropping downward.
(6) Tighten fitting bolts and plugs using a torque wrench with standard torques
shown on the drawing of each size.
 9
№ Work Notes
(1) The place must be clean.
Select an appropriate place to assemble.
1 (2) Spread rubber sheet, cloth, etc. to
prevent parts from being damaged.
Fit swash plate support in (251) in (1) In case servo piston, tilting pin,
pump casing (271). servo bias springs, spring seat, and
plug were removed, reinstall all
parts before fitting swash plate
support.
(2) Be careful not to clamp fingers by
springs when installing springs.
(3) Use a special jig not to damage head
part of tilting pin and feed-back pin.
2 Apply adhesive (Three bond No.
1305B) on thread of servo piston.
(4) Pin (884) has been installed on the
inside surface of pump casing. When
installing swash plate support, make
sure that pin enters into the slit of
swash plate support(251).
(5) Be careful not to install swash plate
support (251) in oblique.

Insert tilting pin(530) of the servo piston (1) When inserting, while pushing down
(532) sub-assembly into tilting bush of servo piston, insert tilting pin into
swash plate assembly (030), then install tilting bush and insert swash plate
swash plate assembly (030), and shoe into grove of swash plate support
plate (211) in pump casing (271). correctly.
(2) If grease is applied on rounding
surfaces of swash plate and swash
plate support, it is easier to install.
3
 10
№. Work Notes
Insert drive shaft (111) into pump casing (1) When tapping shaft, keep shaft in
(271) tapping shaft lightly so that height vertical direction.
of surface of the pump casing and height If tapped strongly, roller bearing
of end of roller bearing are nearly the may be broken.
same. (2) Be careful not to push the top
surface of roller bearing deeper than
the surface of pump casing. If the top
surface is deeper than the surface of
pump casing, there is a possibility for
swash plate support to be detached.

Tape the splined or keyed area of the (1) Apply a little grease on lip of oil seal
shaft. installed in seal cover.
Insert seal cover (261) slightly into (2) Be careful not to damage lip of oil
pump casing. seal.
In case of K3VL80, 112, 140, tighten (3) Make sure to tighten the four
hexagon socket head bolts (406) hexagon socket head screws evenly.
uniformly to stopping position of the (4) In case of K3VL45, install
seal cover and then tighten bolts with a O-ring(710), apply grease on outside
standard torque. surface of seal cover, and be careful
In case of K3VL45, use the hammer to not to damage O-ring(710).
lightly tap the seal cover to the position
where the groove for locking ring can be
5 seen and then install retaining ring
(406).
 11
№ Work Notes
Assemble cylinder (141), piston-sub (1)Incase of K3VL45/A
(011), spherical bush (156), set plate Install cylinder spring, ring guide,
(153), and cylinder spring (157) into a and retaining ring into cylinder and
sub assembly. then assemble pin, spacer, spherical
bush, set plate, piston-sub to set a sub-
assembly.
(2) Be careful not to damage sliding
6 surfaces between piston and cylinder
bore, and between cylinder and valve
plate.

Place pump casing (271) horizontally (1) Be careful not to drop parts for
with surface of regulator downward. piston-cylinder sub such as cylinder
Install piston-cylinder sub into pump spring and roller.
casing. (2) Be careful not to damage
bearing-contacting surface of the
shaft when installing a piston-
cylinder sub.
7

Install valve plate (313) on valve cover (1) In case that stopper (534), max flow
(312). set screw (954), and max flow set
screw lock nut (808) have been
removed, install these parts on valve
cover (312) beforehand.
(2) Do not mistake suction/delivery
direction of valve plate (313). When
8
installing valve plate, make sure that
pin (885) enters into the slit of valve
plate (313).
(3) If grease is applied on contacting
surfaces of valve plate (313) and valve
cover (312), it is easier to install valve
cover (312).
 12
№ Work Notes
Install valve cover (312) on pump casing (1) In assembling valve cover, be careful
(271). not to damage shaft and contacting
Tighten hexagon socket head bolts (411 surface of needle bearing.
in case of K3VL45, 80), (411 and 412 in
case of K3VL112, 140),

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

10
 13
Attached Drawing No.1 Exploded Drawing
 14
2 Judging Standard for Maintenance
2-1 Judging Standard for replacing worn parts
When each part is worn exceedingly over the following standard, replace or
adjust the part. If there is a remarkable damage, replace or adjust the part.
( Upper：standard of initial value, Lower：standard of limit for replacing)
standard of initial value /
Measuring item
standard of limit for replacing Measure
140
Clearance between 0.039 Replacement of piston or
cylinder bore and
piston (D-d) 0.067 cylinder
Endplay between ≦0.1 Replacement of piston-shoe
piston and shoe (δ) 0.3 assembly
4.9 Replacement of piston-shoe
Depth of shoe (t)
4.7 assembly
Free height of 39.5 Replacement of cylinder
cylinder spring (L) 38.8 spring
Combined height 23.0
of set plate and
Replacement of set plate
spherical bush
(H-h) 22.0

(unit:mm)

Clearance between cylinder bore and

Free height of cylinder springs (L)
piston. (D-d)

Endplay between piston and shoe (δ) Combined height of set plate and
Shoe thickness (t) spherical bush (H-h)
 14

2-2 Judging Standard of cylinder, valve plate, swash plate, and

shoe plate
Roughness of standard of limit for
Valve plate (sliding surface), 3-Z
repair
Swash plate (surface
contacting with shoe plate), standard of initial value
0.4Z or less
Cylinder (sliding surface) or after repaired
 INSTRUCTIONS MANUAL

6-3. COUNTERBALANCE VALVE

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6-4. CONTROL VALVE

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 INSTRUCTIONS MANUAL

Control valve

1) Structure (Refer to the assembly sectional drawing)

2) Description of operation

① In stopping operation
Due to the port P1 being closed, pressurized oil from the hydraulic
pump can not flow and the hydraulic motor will be stopped.

② In winding operation
In the assembly sectional drawing, (A) is taken for the restriction part
Composed of a port provided on the spool and edge part of casing.
Likewise in the same drawing, (B) is taken for the restriction part composed of
a notch provided on the compensator spool and an edge of the spool.
With the handle operated towards the winding side, the spool moves toward to
make pressurized oil flow in order of such as P port → restriction part (B) →
P1 port → restriction part (A) → A port → hydraulic motor → B port → T
port and the hydraulic motor will be rotated in a speed according as inclination
of the handle.

③ In slacking operation
With the handle operated towards the slacking side, the spool moves
Downward to make pressurized oil flow in order of such as P port →
restriction part (B) → P1 port → restriction part (A) → B port → hydraulic
motor → A port → T port and the hydraulic motor will be rotated in a speed
according as inclination of the handle.

④ Pressure compensating function

The flow from A port to the hydraulic motor in above mentioned b) In winding
operation, or the flow from B port to the hydraulic motor in c) In slacking
operation are maintained in a constant in proportion to the handle

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 INSTRUCTIONS MANUAL

manipulating angle with the following function, regardless of variation of load

pressure. Namely, the flow of pressurized oil shown in above mentioned b)
or c) provides generated pressure differential between its before and behind
while passing through the restriction part of flow (A).
However, upstream pressure of the restriction part (A), i.e. pressure of P1 part,
is introduced into the chamber (a) and downstream pressure of the restriction
part (A), i.e. pressure of A port, is introduced into the chamber (b), so that the
compensator spool will move due to oil pressure in the chamber (a) against oil
pressure in the chamber (b) and the spring force to regulate pressure of P1
port through the restriction part (B) until both force to be balanced, and then
to be held there.
If pressure differential between before and behind of the restriction part (A)
varies from this condition due to variation of load pressure, the balancing
relationship of the compensator spool again moves to the position keeping
balance to regulate pressure differential between P1 port and A port in a
constant at all times and maintains a constant flow.

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 INSTRUCTIONS MANUAL

6-5. REGULATOR FOR HYD. MOTOR

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 INSTRUCTIONS MANUAL

Regulator for hyd. motor

Operating principle

This regulator installed on the hyd. motor of the winch keeps the power of winch
constant.
The power is proportional to the product of the load and the speed, so that the
Relation between load and speed can be shown in the figure below.

As the regulator installed on a hyd. motor is so designed to adjust the motor

Displacement according to the load, the speed of the winch is increased when
the load s light and decreased when the load is heavy.
The details are as follows.
The pressure oil is directed through the selector valve at port A, B and H of the
regulator. When the load is light, the spring B(201) pushes the spool (108) of the
regulator to the right.

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 INSTRUCTIONS MANUAL

The pressure at port H is supplied to port Y and pressed the drum for changing
displacement of the motor against the minimum displacement side. As a result,
the displacement of the motor becomes minimum and the speed of the winch
becomes maximum.
If the load is increased, the piston (110) and the spool (108) are pushed toward
the left, and bend the spring B (201) by raising the pressure.
When port H is led to port X, the pressure at port H is applied to the drum. The
drum moves toward the maximum displacement side and keeps that position
according to the load. The speed of the winch is decreased in proportion to the
distance of the drum movement.
In case the load is increased greatly, the drum is so pressed against the
Maximum displacement side that the speed of the winch becomes minimum.

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 INSTRUCTIONS MANUAL

6-6. RETURN FILTER

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INSTRUCTION FOR RETURN FILTER

-MODEL (FRs16-20*16F-049)

(FRs20-20*20F-049)
1. Installation
The filter should be installed in a pipeline so that the arrow on the filter
casting is directed from the downstream side to the upstream side of the
pipeline.
The construction and dimensions of the filter are as shown on the
separate drawing.
2. Filtering
The fluid flow into the filter casing, and is, through the filter element, led to
the outlet.
If the filter element in the casing is loaded, the differential pressure across
the element rises until the differential pressure reaches the preset bypass
pressure at which the bypass is actuated for safety’s sake.
3. Loading Detector
(1) Purpose
The detector purposes indicating the loading condition of the filter
element.
(2) Function
The indication ring of the detector moves depending on the degree of
loading.
The detector consists of a indication
post colored to three zones, white,
yellow and green, and a red indication
ring.
In normal operation, the indication ring
lies in the green zone and the ring rises
along the post as the loading of element
increases.

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 INSTRUCTIONS MANUAL

The relationship between the position of the ring and the differential pressure
across the filter element is as follows :
The position of the Start point Boundary Line At Maximum Rise
indication ring between Green
and Yellow
Differential pressure 0.05 MPa 0.12 MPa 0.18 MPa
2 2
of element (0.5 kgf/cm ) (1.2 kgf/cm ) (1.8 kgf/cm2)
Preset bypass valve 0.2MPa
pressure (2 kgf/cm2)

<<Caution>>
Even if the indicator points to the yellow zone as a result of some loading of
filter element, the indicator returns to the position of normal condition (green
zone) after the operation stops.
Be sure not restart the operation without taking necessary measure only by
reason that the detector indicates green after the operation has stopped.

4. Disassembly, Cleaning and Reassembly

(1) Disassembly and reassembly
At the time of a periodical inspection or
when the detector indicates loading of the
filter element (the indication ring rises to
cover the entire green zone), take out the
element by the following procedure, and
clean or replace it.
(a) Disassembly, Assembly
Ⅰ. Loosen hexagon head socket bolt ①
and then remove the cover ②.
Ⅱ. It take care to pull out element knob ③
element ⑤.
Ⅲ. The assembly of the filter should be
carried out in reverse order of
disassembly.

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 INSTRUCTIONS MANUAL

Ⅳ. Cover bolts ① should be tightened in the diagonal order.

※ Gaskets and O-ring should be replaced with new ones at proper

intervals of time.

(2) Cleaning or replacing

(a) If the element is stainless steel it can be reused by means of following
method.
Wash the element well in kerosene and blow it with air.
After compilation of the cleaning as above, further clean the element by
od supersonic cleaning.
(b) If the element is paper, Change the element to new one.

(3) Time of element replacement

(a) If the loading of element is observed earlier than usual after restarting of
operation with the cleaned element, replace the element with a new one.
(b) Repeated cleaning or regeneration of the element has a tendency to reduce
the recovery rate or to cause abnormal defects such as enlargement of
opening. Replace the element with a new one after every two years of
service.
(c) In the case of paper element, immediate replacement with a new one is
required when the indication ring of the detector has come to cover the
entire green zone of the indication post.

※ For filters without a detector, the periodical inspection of the filter element
should be carried out.

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6-7. OIL COOLER

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 INSTRUCTIONS MANUAL

6-8. FAIL-SAFE BAND BRAKE

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 INSTRUCTIONS MANUAL

GENERAL
According to chapter 7.4.6 in OCIMF mooring equipment guidelines, this fail-safe brake is
designed and manufactured for setting a correct brake holding load for a spring applied
manually operated band brake.

OCIMF mooring equipment guidelines 3rd Edition (MEG3) is as follows :

The primary brake should be set to hold 60% of the mooring line’s MBL. Since brakes may
deteriorate in service, it is recommended that new equipment be designed to hold 80% of
the line’s MBL, but have the capability to be adjusted down to 60% of the line’s MBL.
When testing spring-applied brakes, it is important to bear in mind that, in service, the brake
band will rotate some quarter to half a turn beyond the initial slipping point experience when
tested before full holding load is achieved. Therefore, for spring-applied brakes, the final
holding load will be higher than the initial slipping load recorded. This load could be
10~20% above the test load due to a combination of the servo effect in the brake and the
spring force acting on the brake screw, which compensate for the elongation in the brake
band and mechanism. Should a spring-applied brake be tested to 80% of the line’s MBL,
the final brake holding could be 90~100% of the MBL. It is therefore important that
spring-applied brakes are tested and adjusted to render at no more than 60% MBL resulting
in a final brake holding load of about 70~80% of the MBL as below illustrated figure 1.

< Figure 1. Effect of Slippage on Final Brake Holding Load – Spring-Applied Brakes >

2/7
 INSTRUCTIONS MANUAL

DESCRIPTION
The fail-safe band brake setting device consists of following main items :
-. No. 101 : Handle
-. No. 102 : Brake setting device
-. No. 103 : Loose block
-. No. 104 : Block
-. No. 105 : Indicator
-. No. 106 : Indicator ring
The brake is operated manually by turning the brake handle.

101

104 105 106 103 102

101 - HANDLE -
102 - BRAKE SETTING DEVICE -
103 - LOOSE BLOCK -
104 - BLOCK -
105 - INDICATOR
106 - INDICATOR RING

The setting device consists of following main items :

-. No. 201 : Bearing housing
-. No. 202 : Thrust ball bearing
-. No. 203 : Disc springs
-. No. 204 : Ring
-. No. 205 : Locking nuts (For indicator)
-. No. 206 : Sleeve

3/7
 INSTRUCTIONS MANUAL

206 205 204 203 202 201

201 - BEARING HOUSING -

202 - THRUST BALL BEARING -
203 - DISC SPRINGS -
204 - RING -
205 - LOCK NUTS FOR INDICATOR -
206 - SLEEVE -

The brake setting device consists of bearing housing, thrust ball bearing, disc springs,
ring, locking nuts and sleeve. If the disc springs is operated higher pulling force
than 60% of MBL, the brake will automatically slip at the same set point.

TESTING & SETTING

Test procedures
Use a brake test kit and test the slipping point corresponds with 60% of M.B.L as below :

1. Before brake test, check that the brake lining surface is continuously touched on
brake drum.
2. Tighten the brake of testing drum surely and disengage the clutch.
3. Install the test kit with pin.
4. Put the hydraulic jack on the lower edge point of the test kit. Adjust the height of
hydraulic jack on foundation .
5. While paying attention to each part, raise the pressure by hand operated pump and
read the scale of attached pressure gauge. During jack up operation it is necessary to
tight the brake handle again.
6. Brake holding capacity can be found the gained value from pressure gauge.
7. Repeat test until the slipping point corresponds with 60% of M.B.L
8. When correct setting point of the brake screw is finished, tighten the lock nuts
No. 205.

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 INSTRUCTIONS MANUAL

9. The lock nuts for setting device are adjusted to contact with the bearing housing. It
is crucial to check that there is NO GAP between the two lock nuts and the bearing
housing.
10. Adjust the indicator arrow to correspond to the middle of indicator ring and secure it
by the two bolts.

Calibration
-. Brake setting force : F= M.B.L x 0.6
-. P.C.D of hawser drum (1st layer) : D
-. Hydraulic jack force : Fj= (FxD/2) / L
-. Test pressure : P= Fj / A (A : Effective area of hydraulic cylinder)
Repeat test until the slipping point corresponds with 60% of M.B.L.

F
=D
P CD

Fj
301

302

DECK

BRAKE TEST BRACKET

303 (SHIPYARD SUPPLY)

The brake test kit assembly consist of following main items :

-. No. 301 : Brake test kit
-. No. 302 : Hyd’ jack
-. No. 303 : Hyd’ pump with hose

5/7
 INSTRUCTIONS MANUAL

CAUTION :

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
BRAKES.

Detail of locking and marking device for brake setting

After the brake testing is completed, the lock nut for indicator is correctly adjusted.
Turn the lock nut for indicator (No.205) until the lock nut for indicator touch the bearing
housing (No.201) And then adjust the indicator arrow(No.105) to correspond to the middle of
indicator ring(No.106)

Lock nut for indicator 205

106 Indicator ring Bearing housing 201

GAP

105 Indicator

Consequently it is most importance to check that there is no gap between the two(2) lock
Nuts(No.205) for indicator and bearing housing No.201. If a gap, the brake holding load will
be lower than tested load.

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 INSTRUCTIONS MANUAL

CAUTION :
ALWAYS TIGHTEN THE BRAKE UNTIL THE MIDDLE OF INDICATOR RING
COINCIDES WITH THE INDICATOR ARROW, NEVER BEYOND.
WHEN THE MIDDLE OF INDICATOR RING COINCIDES WITH THE INDICATOR
ARROW AND A GAP OCCURS BETWEEN BEARING HOUSING (201) AND LOCK
NUTS (205), BECAUSE OF ANY WEAR ON THE BRAKE LINING, FIRST OF ALL,
TIGHTEN THE BRAKE SCREW WITH BRAKE HANDLE TO CONTACT THE LOCK
NUT (205) WITH THE BEARING HOUSING (201) AND THEN READJUST THE
INDICATOR ARROW (105) TO COINCIDE WITH THE MIDDLE OF INDICATOR
RING(106).

NOTE
The brake holding force varies depending on the physical condition of the brake linings and
drum. Oil, moisture, rust on the brake linings or drum, or heating of those can reduce the
brake holding force because “Friction coefficient” comes down.
And if contact condition of linings and drum isn’t even all over the contact area, the brake
holding force can also come down due to decline of “Contact rate”.
Then, the needed force to obtain the brake holding force can become two or three times
as large as above “ Needed force for handle”

7/7
*/4536$5*0/4 ."/6"-

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