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- 1 -
INSTALLATION ANDMAINTENANCE MANUAL
AUSTART ATS63TURBINE STARTER
K.H. EQUIPMENT PTY. LTD.14-16 WESTPOOL DRIVE,HALLAM VICTORIA 3803 AUSTRALIAPH: +61 3 9796 4766 FX: +61 3 9796 4878EMAIL: [email protected] WEB: www.khequipment.com.au
Issue: 23/03/2004 Rev. 01
- 2 -
THIS MANUAL CONTAINS IMPORTANT SAFETY INFORMATION. IT IS IMPORTANTTHAT THE ENTIRE CONTENTS BE STUDIED BEFORE INSTALLATION AND OPERATION.
IT ONLY REFLECTS GENERIC INFORMATION RELATING TO A STANDARD AUSTARTATS63 TURBINE STARTER. VARIOUS OTHER OPTIONS ARE AVAILABLE TO PROVIDE
INERTIA DRIVE SYSTEMS, HARSH ENVIRONMENT MUFFLERS OR THREADEDEXHAUSTS TO MEET SPECIFIC APPLICATION REQUIREMENTS.
FOREWORDThis manual contains instructions for theinstallation, maintenance and operation ofyour new ATS63 AUSTART Air StarterMotor. It has been designed to provideyou with safe and reliable service.However, it is both a pressure vessel and apiece of rotating machinery. Therefore,operators and maintenance personnelmust exercise good judgement andappropriate safety practices to avoiddamage to the equipment and preventpersonal injury. The instructions in thismanual are intended for personnel with ageneral training in the operation andmaintenance of air starter equipment.It should be understood that theinformation contained in this manual doesnot relieve the operating and maintenancepersonnel of the responsibility forexercising good normal judgement in theoperation and care of air start equipmentand their associated systems.
Throughout this manual you will encounterthe words WARNING, CAUTION andNOTICE.
These paragraphs are intended toemphasise certain areas where personnelsafety and satisfactory starter operationmay be compromised should the messagebe ignored. The definitions of these wordsare as follows -
An operating procedure, practice etc. thatif not strictly observed, could result inpersonal injury.
An operating procedure, condition etc. thatif not followed could result in damage to,or the destruction of equipment.
An operating procedure, condition etc. thatis essential to highlight and observe.
It is advisable that a safety program beestablished to address the safety issuesdetailed within this manual beforeinstalling, operating or maintaining thisequipment. It is important such a programcovers the hazards associated withcompressed air.
Do not install this starter other than inaccordance with the instructions detailedin this manual.
These instructions should be readcompletely before beginning installationand should be available to personnelresponsible for operating and maintainingthis equipment. The unit is capable oftrouble free operation when properlyapplied, installed and maintained.
Extra copies of this manual are availablefrom your local Austart Air StarterDistributor or the Factory.
This manual is designed to cover allsituations normally experienced wheninstalling, operating and maintaining thisequipment. In the event situations areencountered that are not covered by thismanual, consult your AUSTART agent orK.H. Equipment Pty Ltd direct.
NOTICE
WARNING!
NOTICE
CAUTION
WARNING!
AU
STA
RT
PR
OD
UC
T N
UM
BE
RIN
G
ST
AR
TE
R M
OD
EL
FL
AN
GE
CO
DE
PIN
ION
CO
DE
SP
EC
IAL
FE
AT
UR
ES
MO
DE
L P
RE
FIX
CO
DE
S:
AS
AU
ST
AR
T V
AN
E S
TA
RT
ER
AT
SA
US
TA
RT
TU
RB
INE
ST
AR
TE
R
AS
50A
US
TA
RT
AIR
ST
AR
TE
R01
SA
E 1
099T
H 3
MO
D R
BB
CB
(Ber
ylliu
m C
oppe
r B
ronz
e P
inio
n)
AT
S53
AU
ST
AR
T T
UR
BIN
E S
TA
RT
ER
02S
AE
210
10T
H 8
/10
RE
Thr
eade
d E
xhau
st 1
.5”
AT
S54
(AT
S53
OH
) A
US
TA
RT
TU
RB
INE
ST
AR
TE
R03
SA
E 3
1111
TH
6/8
RG
Thr
eade
d E
xhau
st 2
”
AS
55(A
S50
OH
) A
US
TA
RT
AIR
ST
AR
TE
R04
SA
E 4
1212
TH
8/1
0 R
IIn
ertia
Driv
e
AS
61A
US
TA
RT
AIR
ST
AR
TE
R13
12T
H 8
/10
LK
Kel
ly S
pinn
er M
uffle
r
AT
S63
AU
ST
AR
T T
UR
BIN
E S
TA
RT
ER
Oth
er o
ptio
ns14
11T
H 6
/8 L
MM
inin
g S
pec.
(Cas
t Iro
n)
AT
S64
(AT
S63
OH
) A
US
TA
RT
TU
RB
INE
ST
AR
TE
Rav
aila
ble
1510
TH
8/1
0 L
PM
otor
Por
ts 9
0°
AS
66A
US
TA
RT
AIR
ST
AR
TE
R16
9TH
3M
OD
LS
Sho
rt M
uffle
r
AS
67A
US
TA
RT
AIR
ST
AR
TE
RT
Thr
eade
d E
xhau
st 3
”
AS
68(A
S60
70)
AU
ST
AR
T A
IR S
TA
RT
ER
Oth
er o
ptio
nsU
U C
onfig
urat
ion
AS
69(A
S67
OH
) A
US
TA
RT
AIR
ST
AR
TE
Rav
aila
ble
AS
70A
US
TA
RT
AIR
ST
AR
TE
R
AT
S73
AU
ST
AR
T T
UR
BIN
E S
TA
RT
ER
AT
S74
(AT
S73
OH
) A
US
TA
RT
TU
RB
INE
ST
AR
TE
R
AS
75(A
S70
OH
) A
US
TA
RT
AIR
ST
AR
TE
R
AS
78(A
S70
80)
AU
ST
AR
T A
IR S
TA
RT
ER
AS
80A
US
TA
RT
AIR
ST
AR
TE
R
AT
S83
AU
ST
AR
T T
UR
BIN
E S
TA
RT
ER
AT
S84
(AT
S83
OH
) A
US
TA
RT
TU
RB
INE
ST
AR
TE
R
AS
85(A
S80
OH
) A
US
TA
RT
AIR
ST
AR
TE
R
AS
90A
US
TA
RT
AIR
ST
AR
TE
R
AT
S93
AU
ST
AR
T T
UR
BIN
E S
TA
RT
ER
AT
S94
(AT
S93
OH
) A
US
TA
RT
TU
RB
INE
ST
AR
TE
R
AS
95(A
S90
OH
) A
US
TA
RT
AIR
ST
AR
TE
R
AS
100
AU
ST
AR
T A
IR S
TA
RT
ER
AT
S10
3A
US
TA
RT
TU
RB
INE
ST
AR
TE
R
EX
AM
PL
ES
OF
BA
SIC
ST
AR
TE
R P
RO
DU
CT
NU
MB
ER
ING
AT
S63
-011
0MP
ER
KIN
S 1
006
SA
E1
10T
HM
ININ
G S
PE
CA
TS
63-0
409M
MW
M D
916-
6S
AE
4 9
TH
MIN
ING
SP
EC
AT
S73
-031
1C
UM
MIN
S N
14
SA
E3
11T
HA
TS
73-0
314
CU
MM
INS
N14
SA
E3
11T
HLH
AT
S73
-031
1 ID
ET
RO
IT 1
2V71
SA
E3
11T
HIN
ER
TIA
DR
IVE
AT
S73
-031
4 ID
ET
RO
IT 1
2V71
SA
E3
11T
HIN
ER
TIA
DR
IVE
LH
AT
S73
-031
2MC
AT
ER
PIL
LAR
330
6S
AE
312
TH
MIN
ING
SP
EC
AT
S83
-031
1 IT
WA
UK
ES
HA
707
2S
AE
311
TH
INE
RT
IA T
HR
EA
DE
D E
XH
AU
ST
- 3 -
- 4 -
INSTALLATION AND PREPARATION FOR OPERATION
• Ensure air supply is isolated beforeinstallation, removal, maintenance oradjustment of your AUSTART starter.
• Before any starter is taken out of servicefirst bleed the Air Receiver of air and anymoisture that may have accumulated byopening up the drain valve. Do not bleedby removing Receiver plugs.
• Remove air hoses to ensure completesafety once the air supply has beenisolated and the Receiver has been bled.
• The Air Receiver must be manufactured toan applicable pressure vessel code such asAS 1210, or similar.
• Only use air hoses and fittings that are ofadequate size as indicated in theinstallation schematic (page 6)
• Always carry out a pressure test on thecomplete starting system according toClause 8 on Page 5 before beginningoperation. Do not begin operations untilsatisfied the unit has been installedcorrectly.
• Always use recommended lubricants whereprescribed by this manual. Under nocircumstances use flammable or volatileliquids.
• Ensure all fasteners are torqued to thevalues prescribed in this manual. Usethread sealant where indicated.
• To ensure warranty provisions are notinvalidated use only genuine AUSTARTreplacement parts. Non-genuine partsmay cause service and performanceproblems and may affect the safeoperation of your starter.
PRELIMINARY INSTALLATION REQUIREMENTSNumbers in Brackets refer to Part Nos, refer to exploded view drawing on page 8
1. Your Austart Starter is flange mounted.Before installing the starter carefully studythe mating position of the Austart Starterand engine flanges to determine whetherthe air inlet port orientation or NoseHousing (41) geometry will suit yourparticular installation. If not suitable re-orientate as follows -
• Carefully loosen the Band Clamp (9) butdo not remove. The two housings cannow be rotated relating to each otherwithout separation.
• Re-orientate the Housings to thedesired position and torque the BandClamp (9) to 4 ft lb (6 Nm)
2. Ensure pinion is suitable for engineapplication ie. correct pitch, diameter andnumber of teeth.
3. Check flange to ring gear (FRG) spacing iscorrect and that flange spacers are notrequired. Pinion should be FRG less 1/8”(3mm) when at rest.
4. Check Austart Starter clears all obstaclesand the flange mounts to flywheel housingsquarely without using undue force.
5. Ensure the hoses, fittings and starter portsare clean and free from dirt and foreignobjects. Ensure they remain so duringinstallation.
6. For optimum Austart Starter performanceensure air supply pipes or hoses have aninternal diameter of at least 3/4” (19mm),refer Installation Schematic on page 6. Inthe event line length must be longer than15ft (5m), a size of 1” (25mm) should beused. Keep the number of fittings and thelength of piping to a minimum. Avoid theuse of reducing bushes and other fittingsthat could impede air flow.
WARNING!
- 5 -
INSTALLING THE STARTER AND PIPEWORKRefer to the Starter Installation Schematic drawing on page 6
1. The air supply line should ideally exitfrom the top or side of the Air Receiver.
Do not connect Air Supply Line to thebottom of the Air Receiver. Moistureand system contaminants collect at thereceiver bottom and can damage theAustart Starter internals if allowed topass through. Periodically drainmoisture from the Air Receiver using adrain valve connected at the Receiverbottom.
2. Install a 100 mesh ‘Y’ Strainer. A ‘Y’Strainer installed before the Relay Valvewill provide protection to the Valve andAustart Starter from contaminants thatmay have accumulated in the AirReceiver.
Ensure the inlet side of the ‘Y’ Strainerfaces the Receiver, ie the directionarrow points away from the Receiver.
3. Connect the RV1000 Relay Valve directlyon to the ‘Y’ Strainer using a 1” ShortNipple.
Ensure the inlet side of the Relay Valveconnects to the exit side of the ‘Y’Strainer.
4. Mount the Starter Control Button SC25onto the vehicle dash-board orappropriate control panel and connectto the Air Receiver using a minimum of1⁄4” (6mm) line.
Ensure the inlet side of the StarterControl Button connects to the linefrom the Receiver. Any Safety“Switches” should be installed in thisline between the Starter Control Buttonand the Air Receiver.
5. Determine the practicality of runningthe main air supply hose or pipe fromthe exit of the Relay Valve to the inletof the Austart Starter after the AustartStarter is mounted. It may be easier tofit the hose before the Austart Starter ismounted in position.
6. Once the Austart Starter is mounted, fitthe remaining 1⁄4” (6mm) control linesfrom the Austart Starter to the StarterControl Button and Relay Valverespectively (Refer page 6).
7. Make all hose or pipe connections leakproof using a suitable thread sealant.
8. Once the connections have been madepressurise the system and check forleaks using “soapy” water or similarsolution.
CAUTION
NOTICE
NOTICE
NOTICE
- 6 -
- 7 -
- 8 -
- 9 -
PARTS BREAKDOWN
-X
XX
D
EN
OT
ES
OP
TIO
NS
AV
AIL
AB
LE
AT
S63
/3 (
A)
Rev
.05
17/
09/0
3
AU
ST
AR
T A
TS
-63
Gen
eral
Bui
ld L
ist
Alu
min
ium
Hou
sing
s
ITE
MP
AR
TN
O.
EX
T.
DE
SC
RIP
TIO
NQ
TY
ITE
MP
AR
TN
O.
EX
T.
DE
SC
RIP
TIO
NQ
TY
130
2900
0N
UT
329
6012
000
BE
AR
ING
+1
263
2110
0E
ND
CO
VE
R M
UF
FL
ER
130
6621
000
SE
AL
+1
363
2010
0O
UT
ER
SL
EE
VE
131
6005
000
SC
RE
W6
430
0910
0S
PA
CE
R (
0.62
4”)
332
6317
100
GE
AR
AD
AP
TO
R1
563
1810
0B
AF
FL
E P
LA
TE
133
6730
000
O’ R
ING
+1
630
1210
0S
PA
CE
R (
1.05
0”)
334
6732
000
O’ R
ING
+1
730
1110
0S
TU
D3
3567
2610
0P
IST
ON
18
6319
100
BA
FF
LE
SL
EE
VE
136
6733
500
SE
AL
+1
963
2200
0B
AN
D C
LA
MP
237
6725
XX
XD
RIV
E S
HA
FT
110
6316
300
EN
D C
OV
ER
138
6748
XX
XD
RIV
E A
SS
Y1
1163
2300
0O
’ RIN
G+
239
6734
000
SP
RIN
G1
1263
0100
0S
PE
CIA
L N
UT
140
6731
000
O’ R
ING
+1
1363
1430
0T
UR
BIN
E R
OT
OR
141
6728
XX
XN
OS
E H
OU
SIN
G1
1463
0293
0T
UR
BIN
E H
OU
SIN
G1
4260
2200
0B
EA
RIN
G+
115
6312
100
SE
AL
SL
EE
VE
116
6313
000
PIS
TO
N R
ING
217
6309
000
O’ R
ING
+2
1863
1000
0B
EA
RIN
G+
119
6303
100
RO
TO
R S
HA
FT
163
4090
0S
ER
VIC
E K
IT C
ON
SIS
T A
S M
AR
KE
D +
A.R
.20
6004
000
BE
AR
ING
+1
2163
0800
0C
IRC
LIP
+1
2266
1700
0C
IRC
LIP
+1
2363
0500
0C
OU
NT
ER
SU
NK
SC
RE
W3
2463
0610
0R
ET
AIN
ER
125
6307
100
PL
AN
ET
GE
AR
326
6315
000
BE
AR
ING
+3
2763
1190
0S
PID
ER
HU
B A
SS
Y1
2866
1900
0C
IRC
LIP
+1
- 10 -
- 11 -
MAINTENANCE
DISASSEMBLYRefer to the Cross Sectional and the Exploded View drawings on pages 8 & 10
Begin by removing the two Band Clamps(9) and separate the three Sub-Assemblies;the Nose Assembly, the Motor Assemblyand the Silencer Assembly. Gently tap theassemblies with a soft hammer ifnecessary.
The Sub-Assemblies may now bedismantled separately. Disassembly of anyof these three Sub-Assemblies is detailed inthe exploded view on page 8 and isbasically in the order shown. Refer also tothe following instructions:
Nose Assembly
1. Remove six Screws (31) and separatethe Gear Adaptor (32) by gently tappingit with a soft hammer if necessary. TheGear Adaptor (32) should spring apartfrom the Nose Housing (41).
2. Remove Spring (39), Drive Assembly(38) and Piston (35).
3. Hold Drive Shaft (37) to remove thethree Countersunk Screws (23) whichmay require a sharp tap to loosen them.
4. Remove Retainer (24), Planet Gears (25)and Bearings (26).
5. Support Gear Adaptor (32) in thevertical position, remove Circlip (22)using circlip pliers and gently press outDrive Shaft (37) from Spider Hub (27)and Bearing (29).
6. Remove Circlip (28) using circlip pliersand press out Bearing (29) and Seal(30).
7. Remove Nose Bearing (42) from NoseHousing (41).
Motor Assembly
1. Remove Special Nut (12) by holdingRotor Shaft (19) with the two flatsprovided in a vice.
Do not hold Rotor Shaft by splined endwhen removing Special Nut. Damage tospline will cause premature Gearboxfailure.
2. Remove Circlip (21) using circlip pliersand press out Rotor Shaft (19) throughRotor (13) as an Assembly.
3. Press out Seal Sleeve (15) and Bearing(18) from Turbine Housing (14).
4. Press off Bearing (20) from the RotorShaft (19).
Silencer Assembly
Remove the three Nuts (1) andAssembly will easily come apart.
WARNING!
CAUTION
- 12 -
INSPECTIONRefer to the Cross Sectional and the Exploded View drawings on pages 8 & 10
1. Visually inspect all parts removed duringdisassembly for excessive wear ordamage. Replace any damaged orquestionable parts.
2. Pay particular attention to the vanes onEnd Cover (10) and Turbine Rotor (13)and look for cracks, chipping, warpageor excessive wear patterns. Rotor (13)should fit tightly on to the Rotor Shaft(19). Replace any damaged orquestionable parts. Remove burrs.
3. Also pay particular attention to all gearteeth looking for cracked or brokenteeth and excessive wear. Check thepinion on the Drive Assembly (38) forevidence of unusual contact patternsresulting from misalignment orimproper engagement. Remove anyburrs or replace if questionable.
4. Check all bearings are free to rotate anddo not have excessive play betweenraces. If in doubt replace questionablebearings.
Do not wash shielded bearings that areto be reused in solvent or blow withcompressed air as it may removeinternal lubrication. Bearings that areto be reused should be cleaned bywiping the end shields with a cleancloth.
5. Clean all other parts that are going to bereused with commercially approvedsolvents.
Ensure cleaning operations are carriedout in a properly vented area away fromopen flames.
6. It is recommended that when servicingyour Austart Turbine Starter alwaysreplace complete repair kit contents.
WARNING!
CAUTION
- 13 -
REASSEMBLYRefer to the Cross Sectional and the Exploded View drawings on pages 8 & 10
Reassembly of any of the three Sub-Assemblies detailed in the exploded viewon page 8 is basically in the reverse ordershown. Refer also to the followinginstructions:
Nose Assembly
1. Begin by pressing the Bearing (42) intoNose Housing (41) using a press with anappropriate pressing tool.
2. Drive home the Seal (30) into the GearAdaptor (32) until it bottoms.
Ensure the Seal (30) is fitted the correctway, ie with the tapered leading edgeengaged first. Liberally grease the exposedside of the Seal (30) with Lithium basedgrease such as Valvoline VALPLEX EPGrease or similar.
3. Using a press drive home the Bearing(29) into the Gear Adaptor (32) until itbottoms. Then insert Shaft (37) into theBearing (29) and press home. Ensurethe Gear Adaptor (32) and Bearing (29)are well supported during this operation.Finally fit Circlip (28) using circlip pliers.
4. Invert the Gear Adaptor (32) andrestrain in the vertical position. Slip onSpider Hub Assembly (27) onto Shaft(37) and fit Circlip (22) using circlippliers.
5. Install the three Planet Gears (25) andGear Bearings (26) onto the Spider HubAssembly (27).
Ensure Planet Gears are installed with theboss side of the Gear facing the Spider Hub.Coat Gear Bearings with Grease beforeAssembly.
6. Fit Retainer (24) to the Spider HubAssembly (27) and install the threeCountersunk Screws (23).
7. Invert partial assembly again to fit O-Rings (33) and (40) onto Gear Adaptor(32).
8. Fit O-Ring (34) and Wiper Seal (36) ontoPiston (35).
9. Liberally grease Piston (35), the innerportion of the Gear Adaptor (32) andShaft (37) where it extends, then gentlyslide Piston (35) onto the Gear Adaptorwithout damaging O-Ring (33).
10. Slide Drive Assembly (38) onto Shaft(37) and then fit Spring (39) over DriveAssembly (38).
11.Liberally coat the inner regions of NoseAssembly (41) and Bearing (42) withgrease and assemble Nose Assemblyover Piston (35) taking care not todamage Wiper Seal (36). Rotate theNose Assembly until the six screw holesline up with the Gear Adaptor (32).
12.Squeeze together Gear Adaptor (32) andNose Assembly (41) being careful not todamage O Ring (33), then insert Screws(31).
13. Liberally pack gear teeth with suitablegrease such as Valvoline Valplex EP orsimilar.
14. The Nose Assembly is now ready toaccept the Motor Assembly.
CAUTION
CAUTION
- 14 -
Motor Assembly
1. Begin by lightly oiling the internal boreof the Turbine Housing (14) withhydraulic oil and fitting inner O-Ring(17).
2. Evenly press home Bearing (18) until itbottoms. Ensure O-Ring (17) is notdamaged or dislodged.
3. Install Piston Rings (16) onto SealSleeve (15). Rotate Piston Rings (16) sothat the gaps are 1800 apart.
4. Lightly grease the outside of the PistonRings (16) on the Seal Sleeve (15) andpush home into the Turbine Housing(14) until it bottoms.
5. Press Bearing (20) onto Rotor Shaft (19)using a press and liberally grease top ofbearing.
6. Install 2nd O-Ring (17) into TurbineHousing (14) and insert Rotor Shaft (19)and Bearing (20) as an assembly. Thisshould be achieved with an even pushfit.
7. Install Circlip (21) with circlip pliers.
8. Fit Turbine Rotor (13) onto Rotor Shaft(19) extension. As this is an interferencefit it is necessary to warm the TurbineRotor (13) with a heat gun or boilingwater before installing.
9. Lightly oil thread on Rotor Shaft (19)extension and install Special Nut (12).Tighten Nut against the Turbine Rotor(13) to a torque of 25-30 ft lb.(30-40Nm). Prevent the Rotor Shaft (19) fromturning by holding the flats provided onthe Rotor Shaft (19) in a vice.
Do not hold Rotor Shaft by splined endwhen installing Special Nut as damage canoccur.
Assembling Nose andMotor Assemblies
1. Apply grease to Planet Gears (25) andGear Case (32). Carefully line up splineof Motor Assembly Shaft (19) with thePlanet Gears (25) on the Nose Assemblyand slide the Nose Assembly home.
2. Line up the Nose Assembly and MotorAssembly air inlet ports and install BandClamp (9). Tighten Band Clamp (9) to 4ft lb (6 Nm).
3. Test the operation of the Drive Assembly(38) by introducing air pressure at thecontrol line inlet port. The DriveAssembly should move freely forwardwhen air pressure is applied and backonce the pressure has been relieved.Investigate if this movement is notsmooth.
4. The Nose/Motor Assembly is now readyto accept the Silencer Assembly.
Adding Silencer Assembly
1. Install Silencer Assembly to the TurbineHousing (14). Install Band Clamp (9).Tighten Band Clamp (9) to 4 ft lb (6 Nm)
2. The Austart Air Starter is now assembledand ready for installation. ReferInstallation and Operation section of thismanual.
CAUTION
- 15 -
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 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.
- 16 -
NOTES
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