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ATS83 Mainteneance Manual
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1. 3 a 7 8 9 10 11 12 7322 13 14 16 17 6612 25 26 28 5 clon 1 DENOTES OPTIONS AVAILABLE ATS83 3 A Rev 03 30 08 00 REY 01 21 10 2000 AUSTART TURBINE STARTRR INSTALLATION SCHEMATIC MODEL 41583 AIR SUPPLY FRIN ALL CONTROL AIR LINES KINIH 1 4094 0 0 RH RECEIVER AISR REY 01 3008 00 MAINTENANCE I NINN DISASSEMBLY Refer to the Cross Sectional and the Exploded View drawings on pages 8 amp 10 Begin by removing the two Band Clamps 12 and separate the three Sub Assemblies the Nose Assembly the Motor Assembly and the Silencer Assembly Gently tap the assemblies with a soft hammer if necessary The Sub Assemblies may dismantled separately Disassembly of any of these three Sub Assemblies is detailed in the exploded view on page 8 and is basically in the order shown Refer also to the following instructions Nose Assembly 1 Remove Retainer 28 Planet Gears 29 and Bearings 30 If necessary gently tap the three Countersunk Screws 27 to loosen them 2 Remove nine Screws 47 and separate the Gear Case 35 by gently tapping it with a soft hammer if necessary 3 Remove the two Countersunk Screws 36 The Bearing Housing 38 should spring apart from the Nose Assembly Gently tap the Nose Housing 48 with a soft hammer to
2. Ensure air supply is isolated before installation removal maintenance adjustment of your AUSTART starter Before any starter is taken out of service first bleed the Air Receiver of air and any moisture that may have accumulated by opening up the drain valve Do not bleed by removing Receiver plugs Remove air hoses to ensure complete safety once the air supply has been isolated and the Receiver has been bled The Air Receiver must be manufactured to an applicable pressure vessel code such as AS 1210 or similar Only use air hoses and fittings that are of adequate size as indicated the installation schematic page 6 Always carry out a pressure test on the complete starting system according to Clause 8 on Page 5 before beginning operation Do not begin operations until satisfied the unit has been installed correctly Always use recommended lubricants where prescribed by this manual Under no circumstances use flammable or volatile liquids Ensure all fasteners are torqued to the values prescribed in this manual Use thread sealant where indicated To ensure warranty provisions are not invalidated use only genuine AUSTART replacement parts Non genuine parts may cause service and performance problems and may affect the safe operation of your starter PRELIMINARY INSTALLATION REQUIREMENTS Numbers in Brackets refer to Part Nos refer to exploded view drawing on page 8 Your Austart Starter is flange mounte
3. 38 and Nose Assembly 48 being careful not to damage O Ring 40 then insert Countersunk Screws 36 Slide Gear Case 35 onto Bearing Housing 38 ensuring O Ring 37 is not damaged by smearing oil on the O Ring 37 to allow Gear Case 35 to easily slide over Line up set screw holes and install nine Setscrews 47 Invert the built up Nose Assembly and restrain in the vertical position Install the three Planet Gears 29 and gear Bearings 30 onto the Spider Hub Assembly 31 Coat gear bearings with grease before assembly CAUTION Ensure Planet Gears are installed with the boss side of the Gear facing the Spider Hub Install Retainer 28 to the Spider Hub Assembly 31 and install the three Countersunk Screws 27 Liberally pack gear teeth with suitable grease such as Valvoline Valplex EP or similar The Nose Assembly is now ready to accept the Motor Assembly Motor Assembly Begin by lightly oiling the internal bore of the Turbine Housing 18 with hydraulic oil and fitting inner O Ring 21 Evenly press home Bearing 22 until it bottoms Ensure O Ring 21 is not damaged or dislodged Install Piston Rings 20 onto Seal Sleeve 19 Rotate Piston Rings 20 so that the gaps are 180 apart Lightly grease the outside of the Piston Rings 20 on the Seal Sleeve 19 and push home into the Turbine Housing 18 until it bottoms Press Bearing 24 onto Rotor Shaft 23 using
4. a press and liberally grease top of bearing Install 2 O Ring 21 into Turbine Housing 18 and insert Rotor Shaft 23 and Bearing 24 as an assembly This should be achieved with an even push fit Install Circlip 25 with circlip pliers Fit Turbine Rotor 17 onto Rotor Shaft 23 extension Lightly oil thread on Rotor Shaft 23 extension and install Washer 16 and Special Nut 15 Tighten Nut against the Turbine Rotor 17 to a torque of 25 30 ft Ib 30 40 Nm Prevent the Rotor from turning by using a ring spanner wrench on the special flats provided 11 Assembling Nose and Motor Assemblies 1 Apply grease to Planet Gears 29 and Gear Case 35 Carefully line up spline of Motor Assembly Shaft 23 with the Planet Gears 29 on the Nose Assembly and slide the Nose Assembly home 2 Line up the Nose Assembly and Motor Assembly air inlet ports and install Band Clamp 12 Tighten Band Clamp 12 to 4 ft Ib 6 Nm 3 Test the operation of the Drive Assembly 44 by introducing air pressure at the control line inlet The Drive Assembly should move freely forward when air pressure is applied and back once the pressure has been relieved Investigate if this movement is not smooth 4 The Nose Motor Assembly is now ready to accept the Silencer Assembly Adding Silencer Assembly 1 Install Silencer Assembly to the Turbine Housing 18 Install Band Clamp 12 Tighten Band Clamp 1
5. assist it to separate if necessary 4 Remove Spring 45 Drive Assembly 44 and Piston 41 5 Remove Circlip 26 using circlip pliers and Spider Hub Assembly 31 6 Support Bearing Housing 38 in the vertical position and gently press out Drive Shaft 43 from Bearing 33 7 Remove Circlip 32 using circlip pliers and press out Bearing 33 and Seal 34 8 Remove Nose Bearing 50 and Seal 49 from Nose Housing 48 Motor Assembly 1 Remove Special Nut 15 and Washer 16 Difficulty may be experienced and it will be necessary to restrain the Turbine Rotor 17 from turning by using a ring spanner wrench on the special flats provided 2 Remove Circlip 25 using circlip pliers and press out Rotor Shaft 23 through Rotor 17 as an Assembly 3 Press out Seal Sleeve 19 and Bearing 22 from Turbine Housing 18 4 Press off Bearing 24 from the Rotor Shaft 23 Silencer Assembly Remove the three Nuts 1 and Assembly will easily come apart INSPECTION Visually inspect all parts removed during disassembly for excessive wear or damage Replace any damaged or questionable parts Pay particular attention to the vanes on End Cover 13 and Turbine Rotor 17 and look for cracks chipping warpage or excessive wear patterns Rotor 17 should fit tightly on to the Rotor Shaft 23 Replace any damaged or questionable parts Remove burrs Also pay particular attention to all ge
6. for any consequential damage loss or expense Repeat engine starting attempts must be delayed for 15 seconds to allow all Austart Starter and engine components to stop rotating to avoid damage or adverse wear of components DISTRIBUTED BY 12
7. 2 to 4 ft Ib 6 Nm 2 The Austart Air Starter is now assembled and ready for installation Refer Installation and Operation section of this manual WARRANTY POLICY All Austart Products supplied by K H Equipment Pty Ltd herein called the Manufacturer is warranted to be free from any defect in workmanship and material under conditions of normal use and service for engine starting applications for a period of 12 months from the date of purchase by the first user Normal wear and tear is excluded from the warranty cover The Manufacturer will replace or repair at their works without cost any Austart Starter or parts found to be defective or at their discretion choose to refund the purchase price less a reasonable allowance for depreciation in exchange for the starter or part should the item prove impossible to repair or replace This warranty shall not apply to any Austart Starter or parts which have been altered or repaired or purchased outside the Manufacturer and its assigned agents nor to equipment or parts that have been subject to misuse including overloading neglect accident or damage nor to any part or parts improperly applied or installed This warranty is in lieu of all other warranties and conditions statutory or otherwise expressed or implied and of all other obligations or liabilities on the Manufacturer s part The Manufacturer s maximum liability is limited to the purchase price of the starter and is not liable
8. STARTER AND PIPEWORK Refer to the Starter Installation Schematic drawing on page 6 1 The air supply line should ideally exit from the top or side of the Air Receiver CAUTION Do not connect Air Supply Line to the bottom of the Air Receiver Moisture and system contaminants collect at the receiver bottom and can damage the Austart Starter internals if allowed to pass through Periodically drain moisture from the Air Receiver using a drain valve connected at the Receiver bottom 2 Install a 100 mesh Y Strainer Y Strainer installed before the Relay Valve will provide protection to the Valve and Austart Starter from contaminants that may have accumulated in the Air Receiver NOTICE Ensure the inlet side of the Y Strainer faces the Receiver ie the direction arrow points away from the Receiver 3 Connect the RV1000 Relay Valve directly on to the Y Strainer using a 1 Short Nipple NOTICE Ensure the inlet side of the Relay Valve connects to the exit side of the Y Strainer Mount the Starter Control Button SC25 onto the vehicle dash board or appropriate control panel and connect to the Air Receiver using a minimum of 14 6mm line Ensure the inlet side of the Starter Control Button connects to the line from the Receiver Any Safety Switches should be installed in this line between the Starter Control Button and the Air Receiver Determine the practicality of run
9. TURBINE AIR STARTERS INSTALLATION AND MAINTENANCE MANUAL AUSTART ATSS3 TURBINE STARTER D K H EQUIPMENT PTY LTD 14 16 WESTPOOL HALLAM VICTORIA 3503 AUSTRALIA PH 6139796 4766 FX M 3 9796 4878 EMAIL info khequipment com au WEB khequipment com au THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION IT IS IMPORTANT THAT THE ENTIRE CONTENTS BE STUDIED BEFORE INSTALLATION AND OPERATION IT ONLY REFLECTS GENERIC INFORMATION RELATING TO A STANDARD AUSTART ATS83 TURBINE STARTER VARIOUS OTHER OPTIONS ARE AVAILABLE TO PROVIDE INERTIA DRIVE SYSTEMS HARSH ENVIRONMENT MUFFLERS OR THREADED EXHAUSTS TO MEET SPECIFIC APPLICATION REQUIREMENTS FOREWORD This manual contains instructions for the installation maintenance and operation of your new ATS83 AUSTART Air Starter Motor It has been designed to provide you with safe and reliable service However it is both a pressure vessel and a piece of rotating machinery Therefore operators and maintenance personnel must exercise good judgement appropriate safety practices to avoid damage to the equipment and prevent personal injury The instructions in this manual are intended for personnel with a general training in the operation and maintenance of air starter equipment It should be understood that the information contained in this manual does not relieve the operating and maintenance personnel of responsibility for exercising good normal judgement
10. ar teeth looking for cracked or broken teeth and excessive wear Check the pinion on the Drive Assembly 44 for evidence of unusual contact patterns resulting from misalignment improper engagement Remove any burrs or replace if questionable Check all bearings are free to rotate and do not have excessive play between races If in doubt replace questionable bearings Refer to the Cross Sectional and the Exploded View drawings on pages 8 amp 10 CAUTION Do not wash shielded bearings that are to be reused in solvent or blow with compressed air as it may remove internal lubrication Bearings that are to be reused should be cleaned by wiping the end shields with a clean cloth 5 Clean all other parts that are going to be reused with commercially approved solvents Ensure cleaning operations are carried out in a properly vented area away from open flames 6 It is recommended that when servicing your Austart Turbine Starter always replace complete repair kit contents REASSEMBLY Refer to the Cross Sectional and the Exploded View drawings on pages 8 amp 10 Reassembly of any of the three Sub Assemblies detailed in the exploded view on page 8 is basically in the reverse order shown Refer also to the following instructions Nose Assembly 1 Begin by pressing the Bearing 50 and Seal 49 into Nose Housing 48 using a press with an appropriate pressing tool 2 Drive home the S
11. d Before installing the starter carefully study the mating position of the Austart Starter and engine flanges to determine whether the air inlet port orientation or Nose Housing 48 geometry will suit your particular installation If not suitable re orientate as follows e Carefully loosen the Band Clamp 12 but do not remove The two housings can now be rotated relating to each other without separation e Re orientate the Housings to the desired position and torque the Band Clamp 12 to 4 ft Ib 6 Nm Ensure pinion is suitable for engine application ie correct pitch diameter and number of teeth Check flange to ring gear FRG spacing is correct and that flange spacers are not required Pinion should be FRG less 1 8 3mm when at rest 4 Check Austart Starter clears all obstacles and the flange mounts to flywheel housing squarely without using undue force Ensure the hoses fittings and starter ports are clean and free from dirt and foreign objects Ensure they remain so during installation For optimum Austart Starter performance ensure air supply pipes or hoses have an internal diameter of at least 1 25mm refer Installation Schematic on page 6 In the event line length must be longer than 15ft 5m a size of 1 1 2 40mm should be used Keep the number of fittings and the length of piping to a minimum Avoid the use of reducing bushes and other fittings that could impede air flow INSTALLING THE
12. e Factory This manual is designed to cover all situations normally experienced when installing operating and maintaining this equipment In the event situations are encountered that are not covered by this manual consult your AUSTART agent or K H Equipment Pty Ltd direct AUSTART PRODUCT STARTER MODEL 50 553 54 55 60 561 563 564 AS65 AS66 AS67 AS6070 AS69 AS70 ATS73 ATS74 AS75 AS7080 AS80 ATS83 ATS84 AS85 AS90 ATS93 ATS94 AS95 AS100 ATS103 ATS53 OH 50 OH OBSOLETE ATS63 OH OBSOLETE AS670H ATS73 OH AS70 OH ATS83 OH AS80 OH ATS93 OH AS90 OH NUMBERING FLANGE CODE PINION CODE 01 SAE 1 09 9TH 3MOD R 02 SAE2 10 10TH 8 10 R 03 SAE3 11 11TH 6 8 R 04 SAE4 12 12TH 8 10 13 12TH 8 10 14 11TH6 8L 15 10TH 8 10 L 16 9TH 3MOD L gocuaouzs u SPECIAL FEATURES BCB Beryllium Copper Bronze Pinion Inertia Drive Mining Spec Cast Iron Motor Ports 90 Short Muffler Threaded Exhaust 3 U Configuration Threaded Exhaust 2 Kelly Spinner Muffler EXAMPLES OF BASIC STARTER PRODUCT NUMBERING 630110M 630409M 730311 730314 7303111 7303141 730312M PERKINS SAEI MWM 4 DETROIT SAE3 DETROIT SAE3 DETROIT SAE3 DETROIT SAE3 CATERPILLAR SAE3 10TH 9TH 11TH 11TH 11TH 11TH 12TH MINING SPEC MINING SPEC LH INERTIA DRIVE INERTIA DRIVE LH MINING SPEC INSTALLATION AND PREPARATION FOR OPERATION I NINN
13. eal 34 into the Bearing Housing 38 until it bottoms CAUTION Ensure the Seal 34 is fitted the correct way ie with the tapered leading edge engaged first Liberally grease the exposed side of the Seal 34 with Lithium based grease such as Valvoline VALPLEX EP Grease or similar 3 Using a press drive home the Bearing 33 into the Bearing Housing 38 until it bottoms Then insert Shaft 43 into the Bearing 33 and press home Ensure the Bearing Housing 38 is adequately supported during this operation Finally fit Circlip 32 using circlip pliers 4 Slip on Spider Hub Assembly 31 onto Shaft 43 and fit Circlip 26 using circlip pliers 5 Fit O Rings 37 and 39 onto Bearing Housing 38 6 Fit O Ring 40 and Wiper Seal 42 onto Piston 41 7 Liberally grease Piston 41 the inner portion of the Bearing Housing 38 and Shaft 43 where it extends then gently slide Piston 41 onto the Bearing Housing without damaging O Ring 39 8 Slide Drive Assembly 44 onto Shaft 43 and then fit Spring 45 over Drive Assembly 44 10 9 10 11 12 13 14 15 16 Liberally coat the inner regions of Nose Assembly 48 and Bearing 50 with grease and assemble Nose Assembly over Piston 41 taking care not to damage Wiper Seal 42 Rotate the Nose Assembly until the two countersunk screw holes line up between the nine main stud holes Squeeze together Bearing Housing
14. in the operation and care of air start equipment and their associated systems Throughout this manual you will encounter the words WARNING CAUTION and NOTICE These paragraphs are intended to emphasise certain areas where personnel safety and satisfactory starter operation may be compromised should the message be ignored The definitions of these words are as follows I NINN An operating procedure practice etc that if not strictly observed could result in personal injury CAUTION An operating procedure condition etc that if not followed could result in damage to or the destruction of equipment NOTICE An operating procedure condition etc that is essential to highlight and observe It is advisable that a safety program be established to address the safety issues detailed within this manual before installing operating or maintaining this equipment It is important such a program covers the hazards associated with compressed air Do not install this starter other than accordance with the instructions detailed in this manual These instructions should be read completely before beginning installation and should be available to personnel responsible for operating and maintaining this equipment The unit is capable of trouble free operation when properly applied installed and maintained Extra copies of this manual are available from your local Austart Air Starter Distributor or th
15. ning the 1 air supply hose or pipe from the exit of the Relay Valve to the inlet of the Austart Starter after the Austart Starter is mounted It may be easier to fit the hose before the Austart Starter is mounted in position Once the Austart Starter is mounted fit the remaining 4 6mm control lines from the Austart Starter to the Starter Control Button and Relay Valve respectively Refer page 6 Make all hose or pipe connections leak proof using a suitable thread sealant Once the connections have been made pressurise the system and check for leaks using soapy water or similar solution ATS 83 Exploded view AUSTART ATS 83 General Build List Aluminium Housings PART EXT DESCRIPTION QTY PART EXT NO NO 000 000 900 000 100 3029 000 NUT 8315 3007 100 END COVER MUFFLER 8316 100 100 8021 BAFFLE SOLID 100 SPACER 0 435 BAFFLE LARGE HOLE SPACER 1 050 3006 3009 3004 3010 000 7022 00 8317 DESCRIPTION BEARING STUD BAFFLE SMALL HOLE BAFFLE SLEEVE BAND CLAMP WASHER TURBINE HOUSING SEAL SLEEVE PISTON RING RING 029 e e e WIND o comic N Wit aL on SEAL DRIVE SHAFT DRIVE ASSY SPRING BEARING ROTOR SHAFT BEARING CIRCLIP CIRCLIP COUNTERSUNK SCREW RETAINER PLANET GEAR zs
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