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M22 & M28 Hydraulic Starter Installation Manual

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1. fz pn 3 496 7 SAE 4 10 5mm 9 R 62 2mm Numerous specials are available 045 aN po oe ee fron Powersiar i alana _ MOUNTING FLANGE CL A CE Jiz Gra kas A C A COE FLANGE aan SAEA FLANGE Se ere TA Z SAF3 OAL OU 16 8 11 9mmM WG E 0 661 0 468 e A N ee z ri Fa D m a K e RY Le RSE Z ae J EN L Z NG E s S L L N H EE a TN N B A A AL Se pa a S A jo aS Lo J ee Da ee BS Sn E PCD 104 8mm 4 12 f R 60 0mm 4 PCD 146 7mm R 47 6mm aN Z H 3 DN Publication no M22 MANO1 Release date 11 November 2013 Revision no Page 9 of 12 Hoot Hoot p EM TN TT ras 2 12 g10 200 464 381 349 35 4 IT 5 9 3 145 345 27 0 210 21 6 e 13 8310 20 0 464 41 3 349 35 4 7 12 e8 20 0 571 508 429 43 5 11 8 10 20 0 44 0 349 31 2 31 7 2 75 14 5 33 0 248 20 6 21 1 a1 3 145 41 9 330 285 29 1 14 1012 20 0 41 9 356 328 33 2 10 l3 14 5 381 30 0 245 25 1 E F nnn pra METIE TI nanga G as s 200 470 390 335 341 Pte al met acetone See K 9 80 20 0 368 286 25 4 25 9 L 11 leno 20 0 40 0 350 286 29 0 M 10 1214 200 269 212 187 19 1 N 11 10 12 200 347 28 0
2. SUPPLY LINE TO VALVE START 1 8 MIN SUPPLY LINE TO STAR 3 8 MIN RETURN LINE TO TANK ACTUATION LINE G 1 72 MIN FROM START VALVE 1 8 MIN NOTE 1 RELIEF UNLOADING AND FLOW CONTROL VALVES U TANK RETURN LINE FROM START VALVE NOT SHOWN FOR CLARITY 1 8 MIN TYPICAL HYDRAULIC SCHEMATIC 03 724VD lt Y Y SOLENOID OPERATED M Fig 2 Powerstart pre engaged starter typical schematic Publication no M22 MANO1 Page 6 of 12 Release date 11 November 2013 Revision no V V MIA ul 6 1 ww g9 zr Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters ldN 81 8 140d L31NI ldN HL Z 1 140d 1J11N0 JONVHD LON TIM HLON37 1199350 LNG NOILVENDIANOD NOdN GN3d3G TIM SNOISN3WIG JONV14 3VS ANY 944 7 NWNS 0S ZYH NMOHS 92199 LZ JLON R ul og Ww PZ ful pg ww gg E ul oz ww gog V T Tu ZO ww so s v land C 2 T C d E ul o r ww sz 101g SYSTEMS ___________4 N 0 wtw LerZi 9 M22 Inertia starter d ul 6 Z1 ww z vus Page 7 of 12 Publication no M22 MANO1 Release date 11 November 2013 Revision no 357 mm 14 0 in STARTING SYSTEMS Installation and Operating Instructions for the Powerstart M22 Hydraulic St
3. the user d The defect is not the result of normal wear and tear and e Such starter product has only been repaired by authorised service centres and with parts manufactured or authorised by the manufacturers Powerworks shall at its option either replace or repair without charge any such starter product found upon examination to be defective Repairs or replacements under this warranty are warranted for the remainder of the original warranty period Powerworks makes no other warranty and implied warranties including any warranty or merchantability or fitness for a particular purpose are hereby disclaimed This warranty constitutes the entire obligation of Powerworks relating to the sale and use of this product and Powerworks s or its distributor s maximum liability is limited to the purchase price of such product at the date of purchase In no event shall Powerworks be liable for incidental indirect consequential or special damages of any nature arising from the sale or use of such engine starter product Page 3 of 12 ZR R START Installation and Operating Instructions SS S ESS 5 aso for the Powerstart M22 Hydraulic Starters STARTING SYSTEMS 7 Performance Curves and Specifications E lt 0 o fe O H M22 at 10 MPa 1500 PSI M28 at 10 MPa M22 at 20 MPa 3000 PSI M28 at 20 MPa 1500 2000 2500 3000 3500 Speed rpm Mineral oil ISO 32 to 46 SUS 140 230 Fluid me
4. 25 2 25 6 ep n 2s 145 350 275 238 24 2 R 9 3 200 360 27 0 232 23 7 S 15 ja 145 706 600 526 53 3 T 13 10 12 20 0 398 330 303 30 7 ms an came are uae in aie EE ME MED ZEN T 9 la 200 35 0 27 0 225 23 1 a E Sra TE Hra raTa rren E Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters COT ee ee ee ee ee keeg n af EB BE IO AZ 13 3 145 48 4 424 34 9 355 BZ 11 8 200 405 34 9 268 27 4 cz 15 35 145 61 9 549 46 2 46 8 poz f TE 191 17 6 18 0 EZ 110 12 20 0 296 229 201 205 7 20 0 48 0 39 9 30 6 ez 11 11 2 75 20 0 38 5 30 3 26 1 266 uz 1 ja 200 420 349 293 30 4 aal 543 445 aaa 4 5 20 0 384 LZ 45 5 38 5 31 8 33 4 38 5 31 2 27 3 27 0 39 2 31 8 13 3 5 3 5 3 175 8 10 10 10 13 14 5 46 6 39 0 331 33 7 sz io sio a0 as srel m8 200 9 3 145 351 27 0 21 6 22 2 z uz 9 3 145 32 270 22 7 233 TE EEEE xz it l3 200 411 33 0 27 6 28 2 e a 10 ao 209 229 e 189 goe me BS zrl BTS ao 9 275 O E ETT ee Taa p p TE Ra T z n Flange to Ring Gear Code Table Code s 1 4 5 6 7 8 9 A el of EF EF Publication no M22 MANO1 Release date 11 N
5. Publication no M22 MANO1 Release date 11 November 2013 E Revision no Manufactured by Powerworks Pty Ltd P O Box 50160 Randjiesfontein 1683 South Africa Tel 27 11 203 9900 Fax 27 11 203 9909 e mail info turbinestarters com e Website www turbinestarterst com Powerstart M22 and M28 Hydraulic Starters Inertia and Pre engaged Installation and Operating Instructions STARTING SYSTEMS SAFETY FIRST IMPORTANT SAFETY INFORMATION ENCLOSED Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters Read and understand this manual before operating the starter Failure to properly install or operate the starter may result in damage to the starter and or engine cause personal severe injury and invalidate the warranty Always install operate and maintain this product in accordance with all applicable standards regulations and laws Do not exceed the starter pressure rating as specified on the nameplate Do not work on any starter or starter installation unless all pressure has been drained from the system e Never use damaged fittings or frayed hoses his installation manual should be read and fully understood prior to installation and commissioning of your Powerstart hydraulic starter WARNING Powerstart pre engaged hydraulic starters must be installed and operated in accordance with the instructions given in this document Failure to properly install or oper
6. arters CONSTANT PRESSURE TANK PORT FROM i oo N H oe oo qt NI e ee Ww oO Q wes L Lu F gt er 4 G lt a A gt L 0o N T O r S c gt LO d L 4 ke gt pe gt Q C a C ke e C mn L E U lt t 2 Z Cn ngo lt lt lt 1 G Kd S 2 ked N ES O C d L ra G C E x Da J 4 N c c C t eo be 9 N E amp C E d LO d Publication no M22 MANO1 Release date 11 November 2013 Revision no WILL NOT CHANGE UPON CONFIGURATION BUT OVERALL LENGTH WILL DEPEND FLANGE DIMENSIONS 1 FRG AND SAE 2 50 8MM STARTER SHOWN HAS NOTE ul 6 0 ww pz VIEW A A 1 2 14 NPT OUTLET PORT L gt wo t LJ o 2 v us Oo oa 0 Page 8 of 12 Z E START Installation and Operating Instructions S FS S 35 for the Powerstart M22 Hydraulic Starters Starter model Displacement 10 10cc 16 16cc 22 22CC 28 28CC 38 38cc 66 66cc 0 6 cu in 0 95 cu in 1 35 cu in 1 7 cu in 2 32 cu in 4 0 cu in Drive Type D Inertia P Pre engaged only M22 Gear code Refer to table FRG Flange to ring gear 12 9096 URfeacar vuuco anu voan Refer to table 1 SAE 1 2 SAE 2 3 SAE 3 SAE1 FLANGE NOM 88 8mm 4
7. ate the starter may result in damage to the starter and or the engine cause personal severe injury and invalidate the warranty 2 Orientation of flange Inertia Starter he inertia starter can be oriented to suit the engine configuration and ancillary equipment by removing the four M8 socket head screws which hold the flange to the starter body indexed by 90 increments These screws should be retightened to 35Nm 25 9 Ib ft once the correct positioning has been achieved A 6mm Allen key should be used This will enable the flange to be Publication no M22 MANO1 Release date 11 November 2013 Revision no Repairs should only be undertaken by authorised and trained personnel The use of non genuine Powerstart spares or the servicing by unauthorised personnel may result in safety hazards affect performance and invalidate all warranties Maximum inlet pressure rating is 21 MPa Maximum pinion speed 4000 rpm If slight orientation adjustment of the starter relative to the mounting flange is necessary i e less than 90 then a different flange may need to be used In that event please distributor consult Powerworks or your authorised Pre engaged Starter The pre engaged starter can be oriented by removing the six M6 socket head screws which hold the flange to the front of the starter body The pre engaged flange can be indexed in 60 increments The screws should be retightened to 20Nm 15 Ib ft once the cor
8. dia Viscosity range _ Specifications Overall volumetric efficiency 22 1 CC 28 CC 1 35 cu in 1 71 Cu in Displacement psi 24 kW 31 kW Max power at 3500 rom 32 HP 41 HP Publication no M22 MANO1 Release date 11 November 2013 Revision no Page 4 of 12 ZR START Installation and Operating TTT S E S EE SS E _ E 0 for the Powerstart M22 Hydraulic Starters STARTING SYSTEMS 8 Typical Schematics USING DIRECTIONAL CONTROL VALVE OF EXISTING HYDRAULIC CIRCUIT H OT LNT l N l l l LIV E LN Filler Breather VC 800 a EXISTING VU 5 E 2185 Level Sight Glass Oil Reservoir Starter Motor PUMP _ p _ N r ar lL Z 5 Pressure L ToL AUXILIARY iii Baan Gauge CIRCUIT a EXISTING Hand Pump PUMP pos Foot Valve ee 7 E Z Safety Relief Accumulator ang Mounting Brackets TO RESERVOIR ENGINE DRIVEN PUMP i O ACCUMULATOR Z 5 S E a a a Soo ka _ 4 i z VF ee d 1 VRH 21 ii R 1 STARTER MOTOR D C E N RESERVOIR ke Fig 1 Powerstart Inertia starter typical schematic Publication no M22 MANO1 Page 5 of 12 Release date 11 November 2013 Revision no Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters 2 SS E E SS E STARTING SYSTEMS OIL RESERVOIR ACCUMULATOR
9. e lock nut below the adjuster Hydraulic starting systems require virtually no maintenance apart from replacing the filter element and a periodic check of the gas pre charge pressure and the system pressure Before undertaking any repair work ensure that the hydraulic system pressure is released If in doubt do not loosen anything and call for professional advice Publication no M22 MANO1 Release date 11 November 2013 Revision no Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters When having equipment repaired ensure that the work 19 carried out by an approved workshop equipped to test all components involved This is particularly important with the accumulator which must be subjected to a rigorous inspection be pressure tested under controlled conditions and have a test certificate issued on satisfactory completion of inspection and testing 6 Warranty D er warrants to the original user of the Powerstart starter that the starters are free from defects in material and workmanship for a period of one year from the date of purchase by such user The conditions of this warranty are that a Powerworks is notified within this period by return of such product to Powerworks or its authorised distributor or dealer transportation prepaid by such user b Such product has been installed and used according to its specifications c Such product has not been misused abused or improperly maintained by
10. inion life Higher operating speeds may cause accelerated wear e Ensure engine is in a serviceable condition oil level fuel supply coolant etc Fuel system must be primed e Disconnect engine from load Alternatively if load cannot be disconnected ensure that it is safe to drive the load once the engine rotates and or fires e Activate starter valve e If engine fails to start recharge accumulator with hand pump and repeat above step e Release starter valve as soon as the engine has started e Repeat the starting procedure a number of times to completely purge the system of air e Ifthe system is equipped with an automatic recharge valve check that it is charging the accumulator to system pressure of 21 MPa 3000 psi If the engine turns rapidly for approximately 3 5 seconds and does not start the problem is not with the starting system If oil emerges from the starter motor check that the inlet and outlet connections are correctly connected to the pressure and return lines If a flow control valve is used this must be carefully set as follows Screw the adjustment knob all the way in and then back out by two turns Have someone actuate the start valve and determine whether the engine starts It should not start due to slow cranking Open the adjustment knob until the engine cranks faster and just starts Recharge the system and try the process again Finally open the knob further by half a turn and lock it using th
11. ould a pilot operated manual or solenoid valve be used a flow control valve is recommended to ensure smoother operation especially with beryllium copper pinions c Port sizes are ideally 3 8 and internal passages should not go smaller than this d Valve configuration is a two position two port style 1 e open and closed 4 2 Pre engaged Starter Start Valve The pre engaged starter requires a pilot valve for Operation since the full flow is only seen by the starter motor itself The following parameters should be met a It should be a positive seated poppet style valve b Valve size can be as small as a 1 8 port valve since it is only a pilot valve c Valve configuration is a two position three port 1 e it must dump back to the starter to tank d Do not limit the flow of oil to the starter motor with an orifice 4 3 Bleeding Prior to first operation it is advisable to bleed system of excess air With inertia starters this is best achieved as follows a Depressurise the system completely b Disconnect the return line going from the starter back to the reservoir at the reservoir end and place into a bucket or suitable container c Have an assistant open the starting valve and hold it open d Operate the hand pump until the flow of oil from the starter is free of bubbles Page 2 of 12 STARTING SYSTEMS 5 Starter Operation The maximum pinion speed of 4000 rpm should be observed in order to maintain optimum p
12. ovember 2013 Revision no Page 10 of 12 Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters SYSTEMS IR d lt k ty U 13 M22 Pre engaged Starter Cross section SONIMVEG TWIdSLVWN 40 1118 9l4jl J3dS TSQOW JGHL OL 923229 3592319 JFJONVIA ANY NOINId 40 SHYSEWNN LYVd ANY S119120 404 3LON 9 2 v Ce 1 zs s Ce ODAN ODED et or e oz sr se 62 94 sr rr T T T T w dn dne wn T P T S Pias 7 T T r 7 T 9 HATI TL C aah Page 11 of 12 Publication no M22 MANO1 Release date 11 November 2013 Revision no Z E START Installation and Operating Instructions SS S ESS 5 aso for the Powerstart M22 Hydraulic Starters STARTING SYSTEMS 14 M22 Pre engaged starter parts list and service kits Quantity in service kit Part Number M22 04 BARREL M22 05 PISTON lt SPRING 1 m U 11 12 13 1 1 O KA lA lA Qn l Un 1 5 17 18 19 20 1 M22 64 SLIPPER SEAL PUSHER PAD M22 66 COVER 1 END CAP M22 69 SPRING 1 2 NININININ N Ui WIN eR Ln 1 5 lM IN eR 26 27 28 29 30 31 32 33 34 35 3 7 Ww Qn 37 38 39 1 1 4 1 42 4 KA 47 2 2 Denotes parts not visible on the cross section UJ 1 1 1 1 2 1 4 LT Publication no M22 MANO1 Release date 11 November 2013 Revision no Page 12 of 12
13. rect positioning has been achieved A 5mm Allen key should be used 3 Installing the starter onto the engine D to mating the starter to the engine perform a quick check of the distance from the flange mounting face to the ring gear and compare this to the distance from the starter flange to the end of the pinion gear For inertia starters the distance from the flange face to the end of the pinion gear should be approximately 12 5mm 0 5 in longer than the flange to ring gear when the pinion is wound all the way forward Page 1 of 12 STARTING SYSTEMS For pre engaged starters the flange to pinion distance should be approximately 3mm 0 12 shorter than the flange to ring gear distance when the pinion is retracted E NOTE The inertia starter is supplied with the drive in the forward position The drive cannot be retracted manually since the detents which hold it in the forward position only release under centrifugal force above a certain rotational speed This is normal and the drive will retract after the first start Mate the starter flange to the engine mounting and check that spigot diameters and mounting holes are correct and line up There should not be excessive play between the starter and the starter pocket on the engine when the starter is mated A maximum of 0 25mm 0 01 is permitted Ensure that the correct mounting bolts are used so as not to protrude into the bell housing and touch the fly
14. wheel In particular if another starter is being replaced which is different from this one the flange thickness may differ and the bolts may need to be replaced accordingly Tighten the mounting bolts as indicated by the engine manufacturer and observe any thread locking or flange sealing procedures which may be specified 4 Piping Up and Bleeding T wo typical installation layouts are shown in figures 1 and 2 depending on which starter is used The components may vary in shape or size but there should be at least a hand pump a filter an accumulator with a relief valve and system hoses 4 1 Hose Sizes and port sizes Hose and fittings should be rated to 21 MPa working pressure minimum Hose sizes should be as follows Pressure lines 3 8 Return lines 1 2 Limit the use of sharp elbows in order to stay within laminar flow Inertia starter port sizes Starter inlet port 3 8 NPT Starter outlet port 1 2 NPT Publication no M22 MANO1 Release date 11 November 2013 Revision no Installation and Operating Instructions for the Powerstart M22 Hydraulic Starters Pre engaged starter port sizes Starter inlet port G 3 8 19 Starter outlet port 1 2 NPT Pilot ports G 1 8 28 4 2 Inertia Starter Start Valve The use of the Powerstart foot operated start valve is recommended However if an alternate start valve is required the following parameters should be met a It should be a positive seated poppet style valve b Sh

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