SERVICE MANUAL INSTALLATION MOUNTING ‘The coupling used on the motor shaft should have @ Brinnel Hardness rating of 200 or more, Spline couplings are available from your distributor of HYDROSTAR motors, ‘Coupling female) specications: Tnvolte spline SAE49 “Taper shaft 1/10 Taper = 42 seconds Recommended tightening torque: ‘Nut of taper shaft coupling (194-5 UNC) = 555 Ft. Lbs. ‘Mounting botts(3/4” Grade 5) = 256 Fi. Lbs. ‘Shatt end bolts of spline shaft (1/2-20 UNF)=80 Ft Lbs. ‘The eccentricity ofthe shaft and the coupling should be within 0.002" TIR when the shatt is directly connected to the driven shaft. When assembling the coupling to the motor do not use force, Hf difcully is encountered, check the motors shaft and cou- pling for burrs or nicks. File smooth the interference. If this doesnt solve the problem, check for size; correctly mated Parts will assemble without any pressure. The pilot diameter Cf the mounting bracket is 15.005/15.001 in normal use. For ‘applications where shocks or frequent reversal operation is ntcipated the clearance of the motor plot diameter and the ‘mounting bracket should be within 0.003" TIR. Maintain lubri- cation between shaft and coupling, PIPING ‘Al pars inside the motor are ol lubricated, theretore itis neces- ‘sary to fillthe motor crank case through the highest drain port vith clean ol before operating motor. Return lines from the drain Ports should be piped directy back to the tank without any restrictions, CAUTION: When motor operates with shatt up, an air bleed should be installed through the adlustment pate to insure lubr- cation ofthe front bearing. Consult KYB for information. The typ- Teal ways for piping lines are: Shaft down Shattup Sideways LER HYDROSTAR’ ee BULLETIN NO. $13586-R3 MRH-135 LOW SPEED HIGH TORQUE HYDRAULIC MOTOR HYDROSTAR SPECIFICATIONS Displacement volume 198.9 IN*REV. ‘Maximum continuous pressure 3570 PSI Intermitiont peak pressure 14900 PSI ‘Maximum continuous back pressure 350 PSI ‘Maximum intermittent back pressure 1000 PSI ‘Maximum continuous output torque 5940 FT-LBS. ‘Starting torque at 3570 PS! '5500 FT-LBS. ‘Maximum continuous speed 220 RPM Maximum continuous power 200 HP Moment of inertia (GO*) 1787 LB-IN? Maximum fuid temperature 1785 Dry weight 496 LBS. Internal crank case drain pressure should not exceed 15 psi Use 14" drain pipe for this model and should not exceed 30 fest. ‘The oll evel ofthe reservoir should not exceed 16 feet over the ‘motor if the reservor is located above. Ifthe motor is focated above the reservot, piping should be looped higher than the motor crankoase. BACK PRESSURE “The motor should be operating under sufficient back pressure, though the HYDROSTAR motor can withstand limited vacuum pressure, This consideration insures smooth and safe operation land protects the whole hycraulc system from noise and vibra- tion breakage. The required minimum back prossureis a hal of Idling pressure plus case pressure. (Refer io MRH-135 ind vidual catalog in detail). In any condition, the back pressure studs po ced 105 pl kita 380 pt cone FILTRATION In most applicaions 100 mesh strainer and 25 micron filer is, for HYDROSTAR motors. Buttis advisable to deter- mine the filtration required by the pump manufacturer because ‘pumps are more critcal against the contamination rather thanHYDRAULIC FLUID RECOMMENDATION ‘The fd selected should be a good grade non-detergent mineral cll with additives added for wear resistance, ant-foam, ant'rust, ant-cxidation and extreme pressure. Minimum viscosity of the hydraulic fuid is 120 SUS. However, itis recommendable for Continuous operation to maintain the viscosity between 168 and 345, Viscosity index of 100 or more is desirable, The HYDROSTAR motors can be used with special fluids such as phosphate ester, water ol emulsion or water glycol. Wf the fluid used is phosphate ester, then viton O-rings and shaft seals are required and the supplier must be made aware of this need, PARTS INFORMATION PART LIST (STANDARD MOTOR) For water oil emulsions and water glycol the system pressure ‘must be restricted to 2,000 psi START-UP When the motor is required to rotate clockwise, connect the ‘pressure line to the ol port“R", embossed on the side of valve housing. Just reverse the connections i direction changes. ‘Air must be completely purged from the hydraulic system ttherwise the hydraulic components wil be subject to failure. The HYDROSTAR motor may be purged by operating for a \While under no oad, remciving air by venting piping at highest point. Check also that no air bubbles are present in the tank boore beginning the operation. ‘Make sure all connections are tight Tem DESCRIPTION ‘ory. | GRADE [| iTew DESCRIPTION ry. [ GRADE 1 Motor Housing T c 29 ‘O"Ring—Inter. Passage [5 A 2 | Vale Housing 1 c 32 [Snap Ring—Piston 3 D 3 | Valve Bearing 1 c 3407 [Socket Head Cap Screw, 5 D 4 [Rotary Valve 1 c 347 [Socket Head Cap Screw 0 D S| Vale Seal 6 c ‘35_| Socket Head Gap Screw 40 D 6 | VaheBearing 1 c 36 | Socket Head Cap Screw 4 oD 7 | Valveénd Cap 1 D 37 |” Socket Head Cap Screw 5 oD 85_[ Crank Shaft 7 c 3807 [Spring Washer 3 D ‘Crank Shaft 7 c 397 [Spring Washer 40 D ‘9 | Crank Shaft Front Bearing 1 c 4077 [Spring Washer 4 =D 10 | Crank Shart Rear Bearing 7 c 4107] Spring Washer 3 D 1 ‘Oldham Coupling 1 D 42 | Drain Plug 2 D 12 | Connecting Rod 5 }s 43 | EyeBot 1 D 13 | Piston 5 S21_| Hexagon Nut 1 D 149] Piston Ring 0 c 53T_| Spring Washer 1 D 47] Piston Ring 5 c aT | Plain Washer T D 15 | Con. Rod—Piston Collar Set D ‘Sot | Key 1 c 16 | Cylinder Cap 5 D 7 | -O"Ring—AdjustmentPlate_| 1 a | Con. Rod Retaining Ring 2 c 75___| Socket Headless Set Screw 1 D 18 | Front Cover 7 D 76__ | Lock Fastener T A 19, Adjustment Plate i D 9207 | “0° Ring— Drain Pug 2 A 24 | Shaft Seal 1 x 92 | *0" Ring—Drain Plug 3 A 25 | “0° Ring—Front Cover 7 x 93 [Drain Pug T 0 a ‘0" Ring—Valve Housing 7 cs 94 | *0"Ring—Drain Plug 1 x “0° Ring—Vaive End Cap 7 x 113 | Piston Ring 5 c zt “0 Ring—Oylinder Cap 5 x Notes: 1. Sufix... Ony S-type Spline sha 8. Recommended Tightening Torque. Sufi... Only Taper shat Sura -Ony MEH SW" Sul ony MR Bs St 2, Grade, These parts should be replaced whenever he motors 135 TW-t Ssassembed emst weig age 4s |temae abst SS SP Lbs Grace...These parts shoul be replaced only as matchingpairsand tam 35 M18 temas M8180: 4 ‘wil probably neearoplazeren dung the Me paiad of Nem 38 WE. temas MB 2222 the mato, ema? M20. 275 SFtLoe |Nema? MB 1752 5 Grate C...These ars probably reedrepacement uring thelile Me S2T TUNG 555 SFL-Lts. | tamSZT T%UNC 555- SFt-Lbs. ‘pero of he motor em 75 M8 P= 2FL-Lbs,|lem75 MB 22=2Ft-Lbs Grades pats seldom fever require to be replaced. 4, For part for motors other tan desenueo ner, please contact KYB corp.SECTIONAL VIEWSERVICE INFORMATION REPAIRING MOTORS UNDER WARRANTY Repair work is not to be attempted by anyone other than the personnel of KYB Corporation of America unless otherwise ‘agreed or should be entrusted to the repair shops designated by KYB Corporation of America. ‘The claims under warranty can not be entertained i the motor in question is repaired by the customer. PREPARATION Botore removing the motor from the installation, drain allo within, then cover the ol port area to prevent foreign particles ‘om entering the motor. Before disasembiing the motor, clean Cutside of the motor thoroughly by washing with clean solvent. DISASSEMBLY PROCEDURE 1. Front Cover {@) Postion the motor shalt up and remove the Socket Head Cap Screws (4), using an Alon wrench sort two jacking screws (Mi6P2"", Mt4P2") nthe tapped holes of the Front Gover (16), then evenly retract the front cover. Al this time, pay attention not to damage the shaft and the shaft seal. {b) Remove the Set Screws (75) and unscrew the Adjust ‘ment Plate (18) from the front cover. Remove the O- ‘ing 25), (74), the Shaft Seal (24) and the outer cup of the Front Bearing (8) 2, Oylinder Cap {@) Remove the Socket Head Cap Screws (35) on each Gylinder Cap (1). (0) Using a sore driver, reove the cyinder caps from the Motor Housing (1). check tobe sure no damage oxcur redto the O-ings (28) underneath the cyinder caps. ‘8. Crank shaft (@) Remove the Front Retaining Ring (17) and lit the Con- necting Rod (12 ear of fe ear Retain Fig (b) Lift out the Crank Shaft (8), then remove the Rear Retaining Ring (17) and Oldham Coupling (11). (6) Use a hammer and brass bar rod to remove the Bear- ings (®), (10) from the crank shaft. (¢)_ Care must be taken during the process not to damage the machined surfaces ofthe crank shaft and conne ing rods, 4. Connecting Rod and Piston Assembly {@) Flomove the Piston Assembly (12, (13) (14) (15) (32) (113) from the motor housing by pulling the pistons toward the center of the motor. (b) Position the Piston Assembly, Connecting Rod (12) up and use snap ring pliers to remove the Snap Ring (32). Flemove the two Con Rod-Piston Collars (15) and pull the connecting rod away from the Piston (13). (€) Use piston ring expander to remove the Piston Rings (14) (11) from piston. 5, Valve Housing (a) Postion the motor so that the Valve Housing (2) is up. Be sure not to damage the machined surface on the bottom side. (©) Use an Allen wrench to remove the Socket Head Cap Sorews (37). (© amv eva Housing (2) om he Mt Hong (@) Use Allen wrench to remove the Socket Head Cap ‘Screws (36) and remove the Valve End Cap (7) from the valve housing then press the Rotary Valve (4) out from the valve housing toward the motor housing, Valve Seals (5) of the rotary valve can be easily removed, using the piston ring expander. (0) Press the Bearing (3) trom the Valve Housing (2) ASSEMBLY PROCEDURE 1. Valve Housing. (a) Insert the Valve Seals (5) into the grooves of the Rotary Valve (4), then press the Valve Bearing (6) onto the rotary valve. (©) Insert the Rotary Vaive (4) nto the motor housing from the motor housing side by squeezing the valve seals with piston ring compressor, then press the Valve Bearing (3) into the vaive housing (6) Place the O-ring (27) into the recess inthe face of the Valve End Cap (7) and install on the valve housing lace O-rings (26) (29) in the face of the Valve Housing (2). Install onto the Motor Housing (1). (@) Make sure the rotary valve and valve bearings are all the way into the valve housing toward the valve end cap. 2. Connecting rod and piston assembly Place the Piston Rings (14) (113) into the grooves of the Piston (13). Insert the Connecting Rod (12) into the piston {and assemble together with Colas (15) and Snap Ring (32). Insert the Piston Assembly (12) (13) (14) (15) (82) (113) into the cylinder bores from inside of the motor housing with piston ring compressor. 3. Crank Shaft Press the outer cup ofthe Bearing 10) nto the Motor Hous- ing (1) and the inner races of the bearings into the Crank Shaft (8). Place the Oldham Coupling (11) on the rotary valve with surtace “stamped on the rotary valve and the clcham coupling withthe center of the crank shaft cam. Position the connecting reds ono the crank shaft cam and retain them by Retaining Rings (17). 4, Front Cover Press the outer cup of the Bearing (9) into the Front Cover (18). Insert the O-ring (25), install the front cover tothe motor housing. Press ihe Shaft Seal (24) into the Adjustment Plate (18), Placing the O-ring (74), tighten the adjustment plate to the front cover until the moment of the crank shaft becomes 25 to 32 ft-lbs. Insert Lock Fastener (76) into the threaded hole of the adjustment plate and tighten Set Screw (75). This isto pre- ‘vent the adjustment piate from loosening, 5. Cylinder Cap Cover Cylinder Caps (16) on each cylinder bore. Make sure not to damage O-ring (28) when assembling,RETURNING OF MOTORS UNDER WARRANTY FOR REPAIR ‘All motors or parts which have faled and are returned to KYB Corporation must arrive freight prepaid, The repairing of HYDROSTAR motors or parts that falied, ‘must be done by KYB Corporation of America oF repair shops ‘designated acceptable by KYB Corporation. Claims for war- ranty will not be accepted if repairs done by the customer or ‘an unauthorized repair center, Prior arrangements should be made for the return of the motor by contacting the KYB Corpo- ration Service Department before shipment is made by the customer. Damage or loss of returned articles in transit will be the responsibilty of the buyer. TROUBLE SHOOTING Motors or parts deemed defective and returned for warranty ‘consideration or repair to KYB Corporation must be accom- panied by the buyer's purchase order (and/or debit memo) i ‘applicable. The purchase order must include shipping instruc tions and accompany all aticies returned, even though in-war- ranty repairs will be performed at no charge to the buyer. tis the buyer’ responsibility o assure that sufficient informa- tion accompanies the returned motor to enable warranty WARRANTY POLICY HYDROSTAR MOTORS, Warranty KYB Corporation of America warrants that, at the time of shipment to the Buyer, all HYDROSTAR motors will be free of defects in materials and workmanship and will con- form tosuch drawings and specication as dined by the purchase agreement of sais shipment. In full settlement ofits obligations under this or any other warranty expressed, of im- plied, KYB Corporation of America agrees to replace or correct any defective article or thereot provided notice of such defect Is received In writing prior to expiration of ‘Warranty time period” #s described herein, and provided such defective articie Is. ‘made available for inspection by KY Corporation of America Return ALIYB Corporation of America's request, it ls the responsiblity of the Buyer to return Under ‘he defective article freight prepaid to KYB Corporation of America for inspection. It Warranty upon inspection said article found to be defective, it shall be replaced repaired or the Labor Exclusion defective articles or parts thereof. If the Buyer grants a warranty on such articles of Btchase price etunded at KYB Corporation of Americe's option, Should ine article be found defective in material or workmanship, KY® Corporation of America will credit the buyer for prepaid freight incurred in returning the defective article for Inspection, and felur the article prepaid by surface rensportation per shipping instructions on Buyers purchase ordor. KYB Corporation of America’s liability warranty is limited to the correction or replacement ofthe detective article, or KYB Corporation of America’s option toa refund of the purchase price, Under no circumstances shall KYB Corporation of America be liable for consequential damages. KYB Corporation of America shall not be lable for labor casts for removal or reinstalling ‘eater scope than indicated above, the Buyer will assume the burden of such greater ‘warranty and hold KY® Corporation of America harmless from any claims of third parties ‘based upon such extended warranty WARRANTY TIME LIMITATIONS All HYDROSTAR Models (1) Six (months from the date of first use or 2) Twelve (12) months from date of first shipment from KYB Corporation of America, whichever period expires first (An article may be repaired more than once under this warranty, but the maximum ‘cumulative time period for this warranty shall be eighteen (18) months from date of first shipment from KYB Corporation of America. Service Parts (1) Six (6) months from date of shipment from KYB Corporation of America. VANIUIAIAMAAAAAUUANAA NAAN NAAM (VAAN MAASAI AAA