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2 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
Methodology :This document is intended for manufacturers of machines that incorporate Poclain Hydraulics products. It describes the technical characteristics of Poclain Hydraulics products and specifies installation conditions that will ensure optimum operation. This document includes important comments concerning safety. They are indicated in the following way:
This document also includes essential operating instructions for the product and general information. These are indicated in the following way:
The views in this document are created using metric standards. The dimensional data is given in mm and in inches (inches are between brackets and italic)
Safety comment.
Essential instructions.
General information .
Information on the model number.Information on the mo-del code.
Weight of component without oil.
Volume of oil.
Units.
Tightening torque.
Screws.
Information intended for Poclain-Hydraulics personnel.
25/10/2017 3
CONTENT
Des
crip
tion
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
DESCRIPTION 4
HES STARTER 7
Characteristics 7Main dimensions 8Model code 9
VHES VALVE 11
Characteristics 11Main Dimensions 12Model code 13ACCUMULATOR 14
SD-CT-PWE 15
PWe ECU 15SmartDrive CT PWe electronic overview 16General chart 17PHASES™ CT 18
INTEGRATION 19
Auxiliaries 19Hydraulic scheme 21Wiring 21
4 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
DDESCRIP
Mark Designation Quantity1 Hydraulic Starter 12 Hydraulic Pump 1
3Sequence Valve 1
Electronic Control Unit 14 Tank 15 Accumulator 1
9
2
3
54
Pressurizes the accumulatorfor the next restart.
Stores the oil.
Hydraulic Pump
AccumulatorStores the energy required fora start-up.
Tank
Sequence valveFills and empties the accumulator.
Electronic Control UnitOptimizes the start-up sequence.
+
DESCRIPTION
25/10/2017 5
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
VHES
val
ve
SD-C
T-PW
E In
tegr
atio
n D
escr
iptio
n H
ES s
tart
er
1
TTION
Installed in the main pulley of the internalengine.
Hydraulic Starter
25/10/2017 7
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
HHES STARTERCharacteristics
• Compact• Powerful• Installed on the crankshaft
Operation Hydraulic symbol
Hydraulic starter compatible with 3 to 12 litres displacement engines dedicated to heavy duty application.
Features
Displacement cm3/rev. [in.cu/rev.] 127,5 [7.78]Max. pressure * bar [PSI] 280 [4000]
Max. speed (start/freewheel mode) RPM 800 / 3000
Max. torque N.m [in.lbf] 550 [4800]
Total oil capacity L [cu.in] 0,4 [24.41]Rotating inertia kg.m2 [lb.ft2] 0.025 [0.59]Mass kg [lb] 13,421 [29.58]
T2
T
P
* Operating phase
8 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
Main dimensions
Hydraulic connections
Port FunctionHES2-X-118-X HES2-X-113-X Max pressure
bar [PSI]Connection Standard Connection StandardP HP connection M22x1.5 ISO 6149-1 G 1/2 ISO 1179-1 280 [4061]T Tank connection M27x2 ISO 6149-1 G3/4 ISO 1179-1 10 [145]
T2 Tank connection M16x1.5 ISO 9974-1 M16x1.5 ISO 9974-1 10 [145]
Any contact with petroleum fluid or brake fluid should be avoided. Sensible parts are protected but in case of long term contact, sealing could be damaged.
60 [2.36]
39[1.53]10 [0.39]
226
[8.9
0]
115
[4.5
3]11
5 [4
.53]
96 [3
.78]
96 [3
.78]
4x Ø13 [4 x dia.0.51]
56,3 [2.22]20 [0.79]
100
[3.9
4]99
[3.9
0]
22 [0.87]
P
T
55 [2.17]54 [2.13]15,5
[0.61]
12,5
°12
,5°
4x2 M10x80
Ø141 [dia.5.55]
17 [0.67] 71,1 [2.80] 15,5 [0.61]
162,
5 m
ax. [
max
.6.4
0]
Ø12
6
[dia
. 4.9
6
]
0 -0,2
0 -0,0
08
7,5 [0.29] 73 [2.87]
100,1 [3.94]
T2
25/10/2017 9
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
Model code
C1Cam ring type
cm3/tr [cu.in/rev.]
HES2 127 [4.99] 2
D1Valving typeClockwise RCounterclockwise 1
D2CoverSymmetrical fixation on cover(with screwed ports) 1
D3Connection typeISO 1179-1 (BSPP + spot face) ports 3ISO 9974-1 (metric + spot face) ports 4ISO 6149-1 (metric + cone) ports 8ISO 11926-1 (SAE J514 with O-ring seal) A
S3-6Options
D Special paint or no paintF Special mountingsP Number plate specific to the customer
S1Standard
4 Mechanical free-wheeling
S2Standard
H High efficiency-torque at low speed very regular(piston with special ring)
P1Turning fixationFixation by came screws 8xM10 on Ø141(centering diameter=126) 1
P2Bearing support
A HES standard bearing support (in 2 parts)
H S 2 1 0 0 0 1 A 0 0 4 HE1
C
1 2
D
3 1 2
F
3 1 2
P
3 4 1 2
S
3 4 5 6
25/10/2017 11
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
VVHES VALVECharacteristics
• Only one component to manage CleanStart system
OperationManage the operating phases of the CleanStart system : accumulating, waiting and starting.
FeaturesMax. pressure (cracking pressure) bar [PSI] 330 bar [4700] *Oil max. temperature °C [°F] 90 [194]
Ambient max. temperature °C [°F] 100 [212]
Mass kg [lbs] 7.5 [16.53]
* Accumulator Relief Valve Protection
12 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
Main Dimensions
Hydraulic connections
Port Function Connection StandardMax pressure
bar [PSI]
A Connection to accumulator G1/2 ISO 1179-1350 [5000]M Output for starter supply G3/4 ISO 1179-1
P Inlet from pump G3/8 ISO 1179-1T Output to tank G3/8 ISO 1179-1 1 [14]
Pressure sensorPressure 600 bar [8702 PSI]Power supply 5±0,5 VOutput signal 0,5 - 4,5 VElectrical connection DIN72585 4 pins coding 1
SolenoidsPort Type of connector Voltage
VS1/VS2DEUTSCH DT04-2P
12/24VPACKARD (METRI-PACK)
DIN-EN 175301-803 (HIRSCHMANN)
55[2
.165
]
55[2.165]
22[0.866]
10[0.394]
46,458
,8
9[0
.354
]
[1.8
26]
[2.3
15]
25[0
.984
]61
,5[2
.421
]
[0.787]20
[0.7
87]
20
58,2
[2.2
91]
85[3.346]
20[0.787]
137 [5.394]
51 [2
.008
]
25[0.984]
28,5
[1.1
22]84
,5 [3
.327
]
105
[4.1
34]
59 [2
.323
]
194
[7.6
38]
23[0.906]
105 [4.134]
175 [6.889]
140
[5.5
12]
75 [2
.953
]48
[1.8
89]
65 [2
.559
]
47,5
[1.8
7]14
[0.5
5]
M
P
T
A
VS2VS1
MA
25/10/2017 13
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
Model code
SequencesVS1 VS2
Accumulator charging On OffP to AP max = 300 bar [4300 PSI]M to T
Accumulator charged pump in by-pass mode Off Off
P to TA max = 300 bar [4300 PSI]M to T
Motor starting Off On P to TA to M
Manual accumulator discharging ( A to T) : unscrew by-pass screw one revolutionAccumulator protection by relief valve (cracking pressure) : 330 bar [4700 PSI]
0- B000SH -EV -
C1-3Volume of tankWithout tank 0002 liter 020
D4Pressure wensor/switch Without 0Sensor 1Switch 2
D5-6Relief valve setting (bar [PSI])250 [3600] 25290 [4200] 29330 [4800] 33
P1Voltage12 V 124 V 2
P2Sensor/Switch connectorWithout 0Bare wire 1Packard (Metri pack connectorseries 150 P2S = 003241171M = IP67)(Metri pack 280 = sensor)
2
Deutch DT04-2P 3Baynet connector DIN 72 5854 pin A53472W = IP69K 4AMP (Superseal 1,5 = IP67) 5
P3Electrovalve S1 connectorDeutsch DT04-2P 3Packard (Metri-Pack) 2DIN EN 175301-803 (Hirschmann) 4
P4Electrovalve S2 connectorPackard (Metri-Pack) 2Deutsch DT04-2P 3DIN EN 175301-803 (Hirschmann) 4
P5Hydraulic connectionsISO 1179-1 (BSPP) 3Metric 4SAE A
-
S1SD-CT-PWEWithout 0SD-CT-PWE integration 1
S2SD-CT-PWE orientationHorizontal HVertical V
1 2
C
3 1 2
D
3 4 5 6 1 2
P
3 4 5 1 2
S
14 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
AACCUMULATOR
Characteristics
• The accumulator stores and restitutes the hydraulic energy needed for next engine start.
Operation
FeaturesMass kg [lbs] 11,6 [25.57]Accumulator volume L [cu.in] 1,5 [91.53]
Design pressure bar [PSI] 300 [4 350]
Test pressure bar [PSI] 450 [6 500]Minimal body design temperature -15°C [5° F]Maximal body design temperature 80°C [176 °F]Thread for GAS filling G5/8
Main dimensions
406 [15.98]
Ø20
[dia
. 0.7
9]
100
[dia
. 3.9
4]G3/
4
25/10/2017 15
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
SSD-CT-PWEPWe ECU
Integrated ECU manages operation CleanStart phases:• Accumulator pressurization• Waiting phase• Engine restart
SmartDrive CT PWE characteristicsCommercial name SD-CT-PWEPart number B03822DOperating voltage 8 V to 32 VOperating temperature -40°C to 100°C [-40 °F to 212°F]Material PA66 30% GF; Silicon (potting)Mass 0,225 kg ±10% [0,496 lb] ±10%Ingress protection (with mating connectors mounted) IP6K9K (ISO20653)12V system max current 17 A24V system max current 8,5 APerformance level Capacity to reach PL d level according to ISO13849:2006 standardMean Time To Failure (MTTF) 162 years (duty cycle is 229 days of 8 hours)Mean Time To Dangerous Failure (MTTFd) 324 yearsDiagnostic Coverage (DC) 95.4 %Category 2Electrical protection Over-voltage, reverse polarity (with fuse), ground and battery short circuitMicrocontroller 16 bits microcontrollerDigital inputs 5Analog inputs (AN) 7Universal inputs 2HSD PWM outputs 4HSD DIG 2,6A outputs 2HSD DIG 0,5A outputs 2Sensor supply 5V 1
Certification E-Marking (2004/104/EC) – Automotive EMC directive
EC-Marking (2004/108/EC) – Agricultural, forestry, construction and forklifts machines
16 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
SmartDrive CT PWe electronic overview
Charging request digital input
Start request digital input
Pressure analog input
T1 Temperature analog input
Engine speed frequency input
CAN Engine speed / EEC1
Charging request CAN input
Start request CAN input
VS1 coil PWM+ output
VS2 coil PWM+ output
VS3 coil PWM+ output
Low error feedback digital output
Critical error feedback digital input
Early start request digital output
System ready digital output
Low error feedback state
Critical error feedback state
Early start request state (CAN)
System ready state (CAN)
Low error feedback state (CAN)
Critical error feedback state (CAN)
Early start request state (CAN)
System ready state (CAN)
Charging request CAN input
Piloting request CAN input
Low error feedback digital output
Critical error feedback digital output
Early start request digital output
System ready digital output
Charging request digital input
Piloting request digital input
SD-CT-PWE-ECU
Vehicle ECU
CAN Bus
by CAN
25/10/2017 17
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
General chart
Engine ON
Clean Start ON
Accumulator charging (until P accu < P needed)
Hydraulics OKHydraulic motordisengagement
Clean Startready
Engine OFF
Low pressure level?(if P accu < P min)
Early Startrequest
Electric start Engine ON
Clean Start OFF
Hydraulic start OK?
Filling request
Startrequest
Safety controls(Temperature, pressure,...)
Thermal engine ormachine state/data
Safety controls(Temperature, pressure ...)
Clean Start/Hydraulic state
NoYes
Yes
No
18 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
Set-upThe settings of the SmartDrive™ CT may need to be changed if there is a change in characteristics or operating conditions. The PHASES™ CT software manages 3 access levels to settings: • Service,• Manufacturer,• Expert.The last two levels are restricted to technicians with specific training (access restriced through password).
DownloadingUsing a PC and the PHASES™ CT software allows to :• Download the software to the SmartDrive™ CT;• Send and retrieve set-up files.
CalibrationThe PHASES™ CT software allows to calibrate the minimum, maximum and neutral positions of the sensors installed on the machine in order to optimize the system’s operation.
DiagnosticsThe PHASES™ CT software enables the user to download the system's operating data. The data collected is used to identify possible malfunctions.
Study of the systemOur sales engineers will analyze your specific needs to facilitate the integration of Poclain Hydraulics components into your system.
TrainingAvailable on request.
PWe pin-out:
PHASES™ CT
Any modification of the value of a setting must be carried out by a qualified engineer trained by the machine manufacturer. The Poclain Hydraulics technical support team can advise you in defining your settings. Modifications to the settings may require a new qualification of the machine. If in doubt, contact your Poclain Hydraulics sales engineer.
For further information, see PHASES™ CT user guide no. A48680N.
[1.1
8]
[2.95][2.95]
[2.3
6][1.2
9]
[1.4
7]
75 75
37,5
30
60
33
[0.21]
40° (2x)
Ø5,5 (3x)1 11 1 1110 20 10 20
12
Connector 1 Connector 2
Connector 3
25/10/2017 19
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
IINTEGRATIONAuxiliaries
CharacteristicsCommercial name KIT-CONNECT-PWE-DIAGPoclain Hydraulics part number B03983DFunction SmartDrive™ CT PWe controller's Counter-part connectors.Compatibility Electronic transmission management with SmartDrive™ CT PWe controller.
Component Molex reference Quantity
Connector 33471-0201 x1
Pin 33012-3003 x2
Wire gauge 0,35 to 0,5 mm² [0.0005 to 0.0007 in²]Insulation diameter 1,2 to 2,69 mm [0.047 to 0.105 in]Operating temperature -40°C to 125°C [-40°F to 257°F]
CharacteristicsCommercial name KIT-CONNECT-PWE-CUSTOMERPoclain Hydraulics part number B03982CFunction SmartDrive™ CT PWe controller's Counter-part connectors.Compatibility Electronic transmission management with SmartDrive™ CT PWe controller.
Component Molex reference Quantity Wire gauge
Connector 33472-2001 x1
Pin 33012-3001 x2 1,5 to 2 mm² [0.0023 to 0.0031 in²]
Pin 33012-3002 x4 0,75 to 1 mm² [0.0011 to 0.0015 in²]
Pin 33012-3003 x14 0,35 to 0,5 mm² [0.0005 to 0.0007 in²]
Plug 34345-0001 x20
Insulation diameter 1,5 to 2,5 mm [0.05 to 0.098 in]Operating temperature -40°C to 125°C [-40°F to 257°F]
20 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
Mounting tools for the connector
CharacteristicsCommercial name KIT-CONNECT-PWE-CUSTOMER-GREYPoclain Hydraulics part number B18082DFunction SmartDrive™ CT PWe controller's Counter-part connectors.Compatibility Electronic transmission management with SmartDrive™ CT PWe controller.
Component Molex reference Quantity Wire gauge
Connector 33472-2002 x1
Pin 33012-3002 x8 0,75 to 1 mm² [0.0011 to 0.0015 in²]
Pin 33012-3003 x12 0,35 to 0,5 mm² [0.0005 to 0.0007 in²]
Plug 34345-0001 x20
Insulation diameter 1,5 to 2,5 mm [0.05 to 0.098 in]Operating temperature -40°C to 125°C [-40°F to 257°F]
Description Molex reference Wire gauge
Crimping tool 63811-5900 1,5 mm2 to 2 mm2
Crimping tool 63811-6000 0,35 mm2 to 1 mm2
Pin extractor 63813-1500
25/10/2017 21
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
Hydraulic scheme
M
P M
MA
A
P
T
T
P
T2
A
B
P2
A
B
PU
T
TU
VS3
Name pin Wire gauge (mm2)DIG-IN 1 0,35 to 0,5DIG-IN 2 0,35 to 0,5ANA-IN 1 0,35 to 0,5ANA-IN 2 0,35 to 0,5+5V out 0,35 to 0,5AGND 0,35 to 0,5+VBAT 1,5 to 2-VBAT 1,5 to 2
PWM 1+ 0,75 to 1 PWM 2+ 0,75 to 1 PWM2- 0,75 to 1 PWM 3+ 0,75 to 1 PWM 3- 0,75 to 1
DIG-OUT 1 0,75 to 1 DIG-OUT 2 0,75 to 1 DIG-OUT 3 0,75 to 1 DIG-OUT 4 0,75 to 1
CAN2-H 0,35 to 0,5CAN2-L 0,35 to 0,5CAN1-H 0,35 to 0,5CAN1-L 0,35 to 0,5
Wiring
22 25/10/2017
CleanStart system / Hydraulic starter POCLAIN HYDRAULICS
1 2
2 P
IN
1 2
1 2
2 P
IN
1 2
1
2
1
2
1 2
2 P
IN
1 2
1 2 3
0.1
GND
GND
VBAT_P5 A
KEY SWITCH
IGN
ITIO
N
STA
RTE
R
CO
M
EMERGENCY SWITCH
15 A
15 A
5 A
20 A
Charging request
Piloting request
HPA pressure sensor
Temperature sensor
+5VS
GNDU
P
+ BATKL 30
STARTER
IGNITIONKL 15
GNDKL 31
25/10/2017 23
POCLAIN HYDRAULICS CleanStart system / Hydraulic starter
HES
sta
rter
VH
ES v
alve
SD
-CT-
PWE
Inte
grat
ion
Des
crip
tion
D
C
BA
J
HG
F
E
1 2
10 P
IN
3 4
1 2 3 45
56
67
78
89
91
01
0
GND
1 2
3 P
IN
3
1 2 3
VBAT_P
C2-6C2-8
SmartDrive CT-PWEPower outDigital input
C1-2
C1-12
C1-11
C1-1
C2-7C2-5
C2-1C2-2
C2-3
C2-4
C3-1C3-2C1-8C1-7
CAN2-HCAN2-LCAN1-HCAN1-L CAN_L
CAN_H
PWM 1+PWM 1-
PWM 2+PWM 2-
PWM 3+PWM 3-
PWM 4+PWM 4-
DIG-OUT 1
DIG-OUT 2
DIG-OUT 3
DIG-OUT 4
Digital output
CAN
C1-3C1-13*
C1-14C1-4C1-15
C2-13C2-14
C2-12C2-15C1-16C1-6C2-16
C2-11C1-17C1-18
C1-19C2-19C1-9C2-10C2-20C2-9
C1-20C1-10
+5V out+5V outAGNDAGND
Digital output
+VBAT SENSOR+VBAT SENSOR GND
DIG-IN 1DIG-IN 2DIG-IN 3DIG-IN 4DIG-IN 5
ANA-IN 1ANA-IN 2ANA-IN 3ANA-IN 4ANA-IN 5ANA-IN 6ANA-IN 7
UN-IN 1UN-IN 1UN-IN 2
Analog input
Universal input
VS2
VS1
VS3
Diagnostic connector(SAE J1939-13)
+ VBAT- VBAT
Power
Low failure
Critical failure
Engine manuallystart
System ready
* C1-13C1 Connector 113 Pin 13
www.poclain-hydraulics.com
25/10/2017
Poclain Hydraulics reserves the right to make any modifications it deems necessary to the products described in this document without prior notification.The information contained in this document must be confirmed by Poclain Hydraulics before any order is submitted.Illustrations are not binding.The Poclain Hydraulics brand is the property of Poclain Hydraulics S.A.
B19278D