SERVICE MANUAL HYDROSTAR’ INSTALLATION MOUNTING Te coupling used on the motor shatt should have a Binnel Hartiess rating of 20 or more. Spline couplings fr sali em your tbr of HYOROSTAR moto, Coupling (emsle) specifications Trvolute spline SAEI4986 Taper shaft 110 Taper = 42seconds Recommended tightening torque Nutot taper shaft coupling (242 UNO) = 820 Ft. Lbs Mounting bats (7 Graces) = S00 tbe ‘haf end ats spine shat SEB UNF) SOF Los, The eccentricity of the shaft and the couping shoul Bevwithin Gotz" IR hen the shat le cy connectes nen assembling the coupling tothe motor do not use force. Il alficuy Is encountered. cheek the motors ‘haf and eouplng for burrs or nsis. File smooth the Imterteranee, thie oesn' aoe the problem, check or Size, eovesty mated parte will sasemble without any pressure. The plot dlametar of the mounting brecket {617.9801 179361 normal use. For applications where shocks or roquont reversal operation fs antlpated the learance of he meter pilot ameter andthe meunting Bracket shouldbe within 0003" TR PIPING Allparis neige the moter areal lubreatse, therfore it Ielnecessary to fil the motor ecank case through the "gest ealn port with clan oi Before operating motor elu oes Yom the dein pots shouldbe pipes cretty Back to the tank without any rostitons. CAUTION. ‘When moter operates with shat up, an ar biewd shoul Be ntaleg trough the ront cove to nsute lubrication Of the tron Bearing. Consult RY for Information, Tne Iyplcal ways for piping lnas are: BULLETIN ss2508-R LEA MR-525 LOW SPEED HIGH TORQUE HYDRAULIC MOTOR HYDROSTAR ‘SPECIFICATIONS Displacement vowume sexo ny REK Maximum continuous pressure ‘000 PSI Invermitent peak pressure ‘3300 Psi Maximum continous back pressure 250 PSL Maximum intermitiet back pressure 1000 Psi Maximum continuous output torque 19820 FT.LBS. ‘Starting torque 3000 Pst 18600 FT. LBs. Maximum continuous speed ‘ORPM Maximum eontinicus power 220HP Momento inertia G0"), 7728 LB.IN! Maximum uid temperature s18°F Dry weight 608 LBs, Internal crank case drain pressure should not excaod Spal Use 34” arn pipe fortis model and should not exceed Soteet Tha ol love of he resarvor should not exoaed 15 feet {ver the mtr the resanoi ia loeated above I the BACK PRESSURE The motor should be operating under sufficient back Drossura, though tha BVOROSTAR motor can with tan limited vacuum pressure. This consideration Sutes smooth and safe operation ana protects the who hyaraueeystem from noise sno vibration breakage, The requredminimum back pressure is rail of idling Dressure pus ease pressure. (Refer to MAS25 inclvidual Eatalog in detain any conciton, the back prssure Should not exceed 1060 pat intrmitnty oF 360 pl FILTRATION pump manutseturer because pumps are more cla {pains econtarination rather han motorsHYDRAULIC FLUID RECOMMENDATION ‘The uid select shouldbe a good grade nondetergent Tinea! of with adctves added for wear resistance, Steam, antvust ant-oxtalon a extreme pressure Minmum viseosity ofthe Pydraute fui is 120'SUS. However, tis recommendebie fer continuous operation ‘oramiain the viscosy between 165 and 348 Vics Index ot 100 9r mores desrabe, The HYOROSTAR motors canbe used with epecial aide Such as phospnate esr, water of! emulsion or wa Bieat The ld used is phosphat {nd shaft ses mae nati For wat ll emulsions and wate col the sytem proseure must be restricts to 2008 PARTS INFORMATION PART LIST (STANDARD MOTOR) thon viton Oxings ‘START-UP {Wen he motor required to rotate clockwise, connect the pressure Ine to the ol por "R embossed onthe “ide of valve housing. vust reverse the connections If fiecton changes ‘ir must be completly purged from te hyauic system ‘tnerwise the nyoraulle components wil be subject 0 {allure The HYOROSTAR motor may be purged by Operating for & while under no loa, remoring alr by ‘venting piping at highest point. Check also that no air ‘unbies are present Inthe tank Botore bogianing tha operation, taht oo aie a ee ae . ita aia Ee Soe oe Leone ioe ert 7 nanan a aa eae am ia ra rae =e tase cle 7 reer ths 26 | “O° Wim — Vata Housing iy 2 | Fasene fe ata = epee St af eaeare iting aah encase en Sa ESS ene feces ew ath ae ee cia aimee i atin ome ateerreematrmctteeme tmnt fie) Binet se RareEXPLODED VIEW SECTIONAL VIEWSERVICE INFORMATION REPAIRING MOTORS UNDER WARRANTY Repair wor snot tobe attempted by anyo ion of America unless fated by KYB Corporation of Ameria, ‘heclams unser waranty cannot be entertained te motor In queston is epaod bythe custom PREPARATION Before zemoving the mato om the instalation, dain alalwihin, then cove the ol port area to prevent fr ign parices trom entering the motor. Before de. seambling the mmol, clean outside of the motor ‘horeughlyby washing with clean sovent DISASSEMBLY PROCEDURE 1. Front over (8, ten evenly retract Me tront ‘over. Atti timo, pay attntion rot togamage the Shaft ang the shat sea (©) Rermowe the Lock Nut 46), Sot Serows (47) and tho Feastonar Soal 2 fromthe Front Gover (1) Remane the Oring 25), the Shaft Seal (20) and the outer {cup the Front Bearing). 2 cylinder cap (a) Remove the Socket Head Cap Screws 8) on each Cylinder Cap 30) (e) Using a screw diver, remove the cylinder caps trom the iotor Housing i. Check tobe sure no damage Sceurred tothe Oxings 26) underneath he einer ope. 3. Crank Shatt (a) Using snap ring ples, remove the Front Snap Ring (33) Lit the Gomecting Rods (12) lear of he Roar Retaining Ring. [P) Lit out the Crank Shalt) then remove the Olsham ‘Coupling (11). Use snap ring pers to remove the ide Ring 7, hammer and brase bar rod to remove the Bearings'B) (10) rom the crank shat. (@Care must be taken during the process not to ‘Samage the machines surfaces of the sank shaft and connecting ods. 44. Connecting Ro ane Piston Assemory (@) Remove the Piston Assembly (12) (19) (14) (15 (92) rom the motor housing by pulling the Pistons (13) toward the piston cap. {© Position the Piston Assembly, Connecting Rog 12) ‘up and-use snap rng pers to remove the Snap Ring (s2h Remove the we Gon RedrPiston Colas (5) and pull the connecting rod away from the Pistontis. (€)Use piston rng expander o remove the Fiston Rings (19 fom piston 5. Valve Housing (@)Poation the motor ao tht the Valve Housing i) = ‘up, Be eure not to damage the machined surface (0) Use ailen wench to remove the Socket Head Cap ‘Screws G7 (@)insert two jacking screws in the tapped oles ofthe vale Nousng ane remove rom the moter Rous. (@)Use Alen wrench to remove the Socket Head Cap Screws (6) ana remove the Valve End Gap (trom {hevalve housing then pros the Rotary Valve) out from the vale Rousing toward the valve ond cap. Valve Seals (2) of the rotary vale can be eae Femoved, using the piston ring expance. (Use he snap ring pliers to remove the Snap Ring (Oi) and prose he outer sup a he eller Boarag 3) Sut font the Valve Housing @ ASSEMBLY PROCEDURE 4. Valve Housing Insort he Vat Seas (6) note prcove ofthe Rotary ‘ave (4 ane pross fo valve nto he Valve Housing 2) tromvaweerd apige, Mo our 2p ofthe Polar ar Ing 9} prensedin the vate housing and hed by Sra fing (St): Presse Valve Boanng@}ntothevahe hous. ing. Beco the Og (27) na th rocaes in the foe of {fe Valve Ena Cap (7) and etal onthe val housing Place the O-ngs (6) (29) nthe ee othe valve Hous Ing (2), talon te Motor Housing (1). 2 Connecting Rad and Piston Assembly Place the Pleton Rings (14) Into the grooves ofthe Piston (13). Reverse the slope ofthe dsassemby ‘recede in rae to reassemble he Piston Assomay. ‘Fron nsert fom cutsige of the motor mousing, 3. CrankSnatt Press the outer cup of the Bearing (10) into the Motor Housing (1) and te Inner races. ofthe Bearings eno the Grank Shaft). Place the Ol CCouetng (1) on the rotary valve with surface". Stamped up. Position the Rer Retalning lg (17) Into the groove of the crank shatt cam with the Rear Snap ring (33) and insert the Crank Sat) Into the motor housing. Make sure to Tne the "L ‘tampa on ota wea te lc cong Postion the connecting ods ont ne crank sft car 4nd vetan them by the Front Betting Ring (17) nd the Front Snap Ring G3 4. Front Cover Prags the outer cup ofthe Front Bearing (@) andthe ‘Sha Sol (24) nto the From Gover (18). Insert the ‘Oring 25 ang instal the front cover to the motor Rousing, igen eveny the A Set Sees (47) against he outer cut he Fret Searing 9) url herman ofthe ark ‘hat becomes 47 to 9 tbe. Lac th st Screws wih Faster Seas (62 and Lock Nu (4) to prevent ine et row ram Iosenig, 5. Gylindor Cap ‘Cover Cylindor Caps (16) on each eylindor bore. Mate our nto damage Oring 28 when seembing,RETURNING OF MOTORS UNDER WARRANTY FOR REPAIR All motors or parts which have faled and are returned to KYB Corporation must arrive right propa “The repairing of HYOROSTAR motors or parte that aod, must be done by KYB Corporation of America or repa ‘hope designated acceplbie by KYB Corpraion Claims {or warantee wll rot be accepted I repar le done by the customer or an unauthorized repair canter Prior arrangements shoul be made forthe return ofthe motor by contacting the KY Corporation Service Department betore shipment is made by the customer Damage or loss of returned articles in transit wil be the responsibility f me buyer TROUBLE SHOOTING Motors or parts deemed detective and returned for warranty consideration o¢ tepait to KYB. Corporation must be accompanied by the buyers purchase ord {andlor debit memo) if applicable. The purchase o most inelude shipping instructions and accompany a aices returned, even though warranty repairs wil be Bortormed at no charge to ho buyer Its the buyers responsibilty to assure that suticient Information accompanies the tuned motor to enable ‘warranty determination to be mace. The following infor ‘ation mustaccompany each unit rotumed, "Customer 2 Dateor etal sale 5: Dateor unt faiure $3 Motor mode! numter and serial number 5 leasonforrelurn or rejection Motor will not turn on, operates erratically couse 4. Overloaded 2 Insutilent system pressure across the motor pot. 5. Crankshaft loosein the bearing 4. viscosity 09 high or too low. 65. Stall when starting orduring at low speed operation, 6. shat coupling detective. 7. Olenam coupling broken. ‘Motor falls off under load cave 2 Excess 8 Oil viscosity to low andlor nigh ol temperature. leakage inside the motor. 'b, Wear damage in the rotary valve piston or piston rings Direction of rotation reverse Cause 1. Piping reverse Oil Leakage couse 1. Shaft seal camapes 2 Reversaof shat sea lp. Solution Reduce th load, ot thre is a pressure conto, in tease the pressure as much as acceptable with factony. ensuite focal cietibutor ether action doesnot ‘correct the situation, ‘check pump andlor rele valve for deterioration. Check to see tereis any passage open fo tank [Adjust th sot screws on front cover so that movernent Of srankahalt Is matched with specific torque. (eter topeged) ‘check the ol viscesty and system temperature. (hetero pages [Adjust the relat vate Inthe sy pressure enough for shalt toturn toincroase the [Adjust oreplace necessary. Replace ne coupiing Solution Check pump output, incorect speed of primary power and orreie valve leakage. Correct any failures. Operate at lower temperature or replace with fue having Viocouty Botween 165 and S48 SUS. Repair or replace the damaged and worn parts. (Rote to pabest ‘solution Correct by reverse plumbing 1 ports Disassemble, revere valve to corect the positioning, Solution Replace the shatt seal. ‘Check crank case pressure and increase of crain port plumbing less than port opening.1. ARHYDROSTAR Mode SAINVANMPAMV ANTON AMVOUPA OO = "Y HYDROSTAR MOTORS = : : = = = = te z = = = = : = VAAAAUARAAANAAMAARAANAMAAONAAARAA Er Wis Ess) America LLC 140 N. Mitchell Court * Addison, Illinois 60101 * e-mail: hyd@kyb.com Phone: 630-620-5555 * Fax: 630-620-8133 » http//www.kyb.com