Motor de Partida - IPU MANUAL Hy-Starter 12072401

Table of Contents
TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................................... 1
2. SELECTION GUIDES ....................................................................................................................2-1

2.1 APPLICATION ENQUIRY FORM..............................................................................................2-1
2.2 SYSTEM SELECTION CALCULATION FORM ........................................................................2-2
2.3 ENGINE CROSS REFERENCE TABLE ...................................................................................2-3
2.4 START VALVE AND RECHARGING SYSTEM DIAGRAMS ....................................................2-7
2.5 HYDRAULIC PIPING AND FITTINGS DIAGRAM.....................................................................2-8
2.6 POWERSTART STARTER PERFORMANCE CURVES ..........................................................2-9
3. INSTALLATION, SERVICE AND MAINTENANCE.......................................................................3-1
3.1 INSTALLATION GUIDELINES..................................................................................................3-1
3.2 MAINTENANCE ........................................................................................................................3-5
3.3 ACCUMULATOR GAS SERVICE .............................................................................................3-7
3.4 ACCUMULATOR GAS CALCULATIONS ...............................................................................3-10
3.5 TROUBLESHOOTING ............................................................................................................3-12
3.6 WARRANTY CLAIM FORM ....................................................................................................3-15
4. ACCESSORIES .............................................................................................................................4-1
4.1 PRESSURE GAUGE SPECIFICATIONS..................................................................................4-1
4.2 RESERVOIR SPECIFICATIONS ..............................................................................................4-2
5. ACCUMULATORS.........................................................................................................................5-1
5.1 ACCUMULATOR SPECIFICATIONS .......................................................................................5-1
5.2 LLOYD’S APPROVAL CERTIFICATE ......................................................................................5-2
5.3 ACCUMULATOR PARTS LIST .................................................................................................5-3
5.4 ACCUMULATOR BRACKET ....................................................................................................5-4
5.5 ACCUMULATOR TEST KIT......................................................................................................5-5
5.6 ACCUMULATOR CHARGE KIT................................................................................................5-6
6. STARTER DRIVE...........................................................................................................................6-1
6.1 STARTER DRIVE SPECIFICATIONS.......................................................................................6-1
6.2 STARTER DRIVE PARTS LIST ................................................................................................6-2
7. FILTERS.........................................................................................................................................7-1
7.1 PRESSURE FILTER SPECIFICATIONS ..................................................................................7-1
7.2 PRESSURE FILTER PARTS LIST............................................................................................7-2
8. MOTORS........................................................................................................................................8-1
8.1 M10 TO M66A MOTOR SPECIFICATIONS & DIMENSION TABLE .........................................8-1
8.2 M10 TO M28 MOTOR DIMENSIONS........................................................................................8-2
8.3 M38A TO M66A MOTOR DIMENSIONS...................................................................................8-3
8.4 M10 AND M16 MOTOR PARTS LIST .......................................................................................8-4
Powerstart Metric Manual

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8.5 M22 AND M28 MOTOR PARTS LIST .......................................................................................8-5

8.6 M38A MOTOR PARTS LIST .....................................................................................................8-6
8.7 M66A MOTOR PARTS LIST .....................................................................................................8-7
9. HAND OPERATED PUMPS ..........................................................................................................9-1
9.1 HANDPUMP SPECIFICATIONS...............................................................................................9-1
9.2 HANDPUMP PARTS LIST ........................................................................................................9-2
10. STARTING VALVES..................................................................................................................10-1
10.1 FOOTVALVE SPECIFICATIONS..........................................................................................10-1
10.2 FOOTVALVE PARTS LIST ...................................................................................................10-2
10.3 CABLE OPERATED SOFT START VALVE SPECIFICATIONS ...........................................10-3
10.4 CABLE OPERATED SOFT START VALVE PARTS LIST.....................................................10-4
10.5 MANUALLY OPERATED SOFT START VALVE SPECIFICATIONS ...................................10-5
10.6 MANUALLY OPERATED SOFT START VALVE PARTS LIST .............................................10-6
10.7 PILOT OPERATED SOFT START VALVE SPECIFICATIONS ............................................10-7
10.8 PILOT OPERATED SOFT START VALVE PARTS LIST ......................................................10-8
10.9 SOLENOID OPERATED SOFT START VALVE SPECIFICATIONS ....................................10-9
10.10 SOLENOID OPERATED SOFT START VALE PARTS LIST ............................................10-10
10.11 MANUALLY OPERATED PILOT VALVE SPECIFICATIONS ...........................................10-11
11. PRESSURE CONTROL VALVES .............................................................................................11-1
11.1 RELIEF VALVE SPECIFICATIONS ......................................................................................11-1

11.2 UNLOADING VALVE SPECIFICATIONS .............................................................................11-2
11.3 UNLOADING VALVE VU-1 PARTS LIST ..............................................................................11-3
11.4 UNLOADING VALVE VU-4 PARTS LIST ..............................................................................11-4
12. ACCUMULATOR, MOTOR AND SYSTEM ORDER CODES ...................................................12-1
12.1 ACCUMULATOR ORDERING CODE...................................................................................12-1
12.2 STARTER MOTOR ORDERING CODE................................................................................12-2
12.3 PINION HOUSING ORDERING CODE.................................................................................12-3
12.4 NOSECONE, FLANGE AND SPACER DETAILS .................................................................12-4
12.5 PINION GEAR AND STARTER DRIVE ORDERING CODES...............................................12-5
12.6 M10 PRODUCT RANGE.......................................................................................................12-6
12.7 M16 PRODUCT RANGE.....................................................................................................12-11
12.8 M22 PRODUCT RANGE.....................................................................................................12-12
12.9 M28 PRODUCT RANGE.....................................................................................................12-16
12.10 M38A/M66A PRODUCT RANGE ......................................................................................12-18
12.11 MINIPAK AND PUMP-PAK ORDERING CODE................................................................12-19
12.12 MINIPAK PARTS LIST ......................................................................................................12-20
12.13 PUMP-PAK DIMENSIONS AND PARTS LIST..................................................................12-21

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September 1999 Page ii
Introduction
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1. INTRODUCTION
0
The year 2000 edition of the Powerstart product manual sees a fresh new approach from previous
editions. The layout of the manual has been changed in order to make it more user friendly and to
provide more input from customers.
The reasons for these changes are customer centred. Firstly, the manual offers more ways for input
from customers to reach Powerstart, in the form of the application enquiry form, the system selection
calculation form, the warranty claim form and also the manual change request form. The changes also
facilitates the release of new editions of the manual, so that the latest up-to-date information is always
on hand. There should be at least two editions per year from now on.
Please feel free to return the customer registration form at the back of the manual in order to be added
to our Powerstart database system. Also bear in mind that we would like this manual to be customer
centred and as such we ask for any comments or constructive criticism which may help us to improve
the level of service which this publication renders.
Powerstart has always been at the forefront of engine starting systems with innovative ideas, the latest
technology and a technical support unparalleled in the industry. We are confident that we will meet the
new millennium with even more innovations, new products and improvements.
The Powerstart technical team.

2nd Edition
September 1999 Page 1-1
Selection Guides
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Application enquiry form
APPLICATION ENQUIRY FORM

General 2. SELECTION GUIDES
1
Customer: Date:
Contact: Machine:
2.1 APPLICATION ENQUIRY FORM
12
Tel. No.: Model:
Fax. No.: Order no.:
Engine Specifications
Make: Model:
Power (kW): Displacement: (litres):
Break away torque: Running torque (Nm):
Parasitic load (Nm):
Min. cranking speed (rpm): Crank duration (s):
Will the load be disconnected from the engine during cranking (Y or N):
Starter Mounting Arrangement
Flange type (SAE 1 or 2 or 3 or 4):
Flange to ring gear (FRG) in mm:
For any special mounting arrangement please supply drawing.
Pinion Gear Information
Pinion gear no. teeth: Ring gear no. teeth:
Pressure angle 15° or 20°): Diam. Pitch or module:
Outside diameter (mm): P.C.D. (mm):
Rotation (CW or CCW): Is a non-sparking pinion required (Y or N):
Existing Starter Motor
Make/model: Power (kW):
Max. overall diameter (mm): Total length (mm):
Specifications are subject to change without prior notice due to product improvements.
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System Selection Calculation
SYSTEM SELECTION CALCULATION

1. Starter Motor
2.2 SYSTEM SELECTION
13 CALCULATION
Ring gear no. of teeth FORM
1.1 Gear ratio = = = :1
Pinion gear no. of teeth
Engine breakaway torque

1.2 Torque required = (inclusive parasitic load)
at pinion = = Nm
Gear ratio (from 1.1)
1.3 Torque required Torque at pinion Nm

= x 1.15 = x 1.15 =
(at starter) (from 1.2 above)
Select a starter from the table below which is supplies a torque equal to or greater than the
torque arrived at in 1.3 above
Starter motor M10 M16 M22 M28 M38A M66A
Maximum torque in Nm
30 48 66 84 124 216
at 21 Mpa (3000 PSI)
Torque req'd System press.

x
1.4 Minimum oil (from 1.3) (21 Mpa) x 21
Nm
pressure = = =
Maximum starter torque in Nm
2. Accumulator
Min. engine Gear ratio rpm

2.1 Starter spd. = x = x =
cranking speed (from 1.1)
Crank duration Starter

x = x
(sec) spd (2.1)
2.2 Starter revs = = revs
60 60
2.3 Min. oil vol. Starter revs Starter dis- cc

= x = x =
required (from 2.2) placement (cc)
Minimum oil vol required

(from 2.3)
2.4 Accumulator ltr.
= = =
minimum size Chart value
Note:
Chart value is obtained from accumulator calculation sheet on section 3, page 3-10
at the intersection of "Maximum system pressure" (recommended 21MPa) and the greater
of "Minimum oil pressure" (from 1.4) or the accumulator gas pre-charge pressure of 10MPa
3. Conclusion
3.1 Starter motor model:
see page 12-2 M __ __ - D __ __ __
3.2 Accumulator model:
see page 12-1 A __ __ __ SC __ - __ __ __ - 00 - N - 0
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Engine Cross Reference Table
2.3 ENGINE CROSS REFERENCE TABLE

14
Engine Capacity Breakaway Starter

Model Cyl. (cc) Torque (Nm) Motor Remarks
ADE
152 3 2510 M22-D318
236 4 3860 M22-D318
354 6 5810 M22-D318
364 4 3970 M22-D5DS
366 6 5960 M22-D5DS
442 V8 15060 M22-D4BS
447 6 11960 M22-D4BS
449 5 9970 M22-D4BS
Baudoin
12P15 V12 82200 M38A-D63S
6P15 6 20550 M38A-D63S
DNP4 4 9140 M22-D63S
DNP5 5 14275 M22-D63S
Caterpillar
3304 4 6970 M28-D23S
3306 6 10463 M38A-D23S
3406 6 M38A-D23S
3408 8 M66A-D73S
3412 12 27000 1170/ROLL M66A-D73S
3508 8 M66A-D73S
3512 12 M66A-D73S
3516 16 M66A-D73S
Cummins
4B 4 3900 M22-DE1S
6B 6 5900 M22-DE1S
6CTA M28-D239
KTA19/28/38/50 M66A-D73S
NTA855 M38A-D73S
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David Brown
580GTLB M22-D3C1
Deutz
BF4M1013E 4 M22-D518
BF6M1013E 6 M22-D518
F10L413 V10 15953 M22-D41S
F12L413 V12 19144 M22-D41S
F3L912 3 2827 M22-D518
F4L912 4 3770 M22-D518
F5L413FRW 5 7977 M22-D5AS
F5L912 5 4712 M22-D518
F6L413 V6 9572 M22-D41S
F6L912 6 5655 M22-D518
F8L413 V8 12763 M22-D41S
Fiat
8210 M22-D4F4
Ford
2700 M22-D3
4500 M10-D3C4XSE
6000 M22-D3C4
GENISIS 6 M22-D3C4
Gardener
6L M22-D23S
Hatz
M40/2/3/4 M10-D444
Z790 M10-D644
Isuzu
2.2 LTR 4 2200 M10-D9G6
6BD1 6 5785 M10-D4P9
C240 4 M10-D9GAXSE
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Iveco
8041-61 M22-D5C6
8210 6 M16-D5F8
8281 SRi 10 V8 17200 M38A-DHRS
Kubota
EB300 M10-DGL1
XXX M10-D5L1
Lister
HL6 6 M22-D21S
PETTER LP2 2 M10-D3M1
PETTER LP3 3 M10-D3M1
PETTER LPW3 3 M10-D3M1
PETTER PH1&2 M10-DLC8XL
STW-2 M10-D318
TS2/3 M10-D318
Man
D0226 M,MT,ML M22-DD18
D2840 T,L,LX,LY M22-D537
D2842 T,L,LX,LY M22-D537
D2848 T,L,LX,LY M22-D537
D2866 T,L,LX,LY M22-D537
Mercedes
OM441A M22-D53S
MTU
183 V6 575 M28-D43S
8V 396 TB33 V8 M66A-DJ
MWM
916-6 M22-D544
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Perkins
1004 M22-D3AS
1006 6 5805 M22-D318
3012 TAG 3A 12 25000 M38A-D63S
4-108 4 1755 M10-D61S
4-236 4 3870 M10-D318
4-248 4 M22-D3A4
SABB
M4/LB 4 2950 108 M10-D544XL
Scania
DS1-14 M22-D43S
VM
D704LT M22-D546
Volvo
1010/1210 SERIES 10-12000 M22-D4AS
1620 SERIES 16000 M28-D2AS
610/710 SERIES Jun-00 M22-D5AS
PENTA 2040 M10-DF46
Yanmar
4TNE84T-JS 4 2500 M16-DTV4
4LH-DTE 4 3455 20 M10-DAG4
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Start Valve and Recharging Systems
2.4 START VALVE AND RECHARGING SYSTEM DIAGRAMS

15
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Hydraulic Piping and Fittings
2.5 HYDRAULIC PIPING AND FITTINGS DIAGRAM

16
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Powerstart Starter Performance Curves
2.6 POWERSTART STARTER PERFORMANCE CURVES

17
2.6.1 M10 AND M16 STARTER TORQUE CURVES

73
60
M10 at 10 MPa (1500 PSI) M16 at 10 MPa
50
40
Torque (Nm)
30
20
10
0
0 500 1000 1500 2000 2500 3000 3500 4000
Speed (rpm)
2.6.2 M22 AND M28 STARTER TORQUE CURVES

74
90
80
70
60
Torque (Nm)
50
40
30
20
10
0
0 500 1000 1500 2000 2500 3000 3500 4000
Speed (rpm)
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Powerstart Starter Performance Curves
2.6.3 M38A AND M66A STARTER TORQUE CURVES

75
250
200
Torque (Nm)
150
100
50
M 3 8 A a t 1 0 M P a ( 1 5 0 0 P S I) M 66A at 10 M Pa
M 3 8 A a t 2 0 M P a ( 3 0 0 0 P S I) M 66A at 20 M Pa
0
0 500 1000 1500 2000 2500 3000 3500 4000
S p e e d (r p m )
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Installation, Service and Maintenance
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Installation Guidelines
3. INSTALLATION, SERVICE AND MAINTENANCE

2
3.1 INSTALLATION GUIDELINES

18
3.1.1 APPLICATION
76
Ensure the use of the correct equipment as requested on the application enquiry sheet and the
subsequent parts list viz.:
• Motor size, mounting flange, pinion gear and direction of rotation.

• Accumulator nominal volume and gas pre-charge pressure.
• Unloading valve flow capacity and pilot drain (internal or external).
• Filter element rating (micron) and flow capacity.
• Reservoir capacity.
• Hose sizes and lengths.
• Starting valve type and options such as engine interlock and transmission interlock.
3.1.2 EQUIPMENT POSITIONING

77
Keep the system as compact as possible. Keep hoses and piping as short as possible. Affix all
equipment properly and effectively to achieve minimal system failure. Items must be easily accessible
for maintenance and testing purposes. Do not mount equipment in close proximity to high temperatures
(e.g. exhaust manifolds etc.).
ACCUMULATOR can be mounted vertically or horizontally. Keep clear of direct engine and
exhaust heat to avoid gas pre-charge variations. Provide a minimum of 100mm
clearance at gas end to permit easy application of test and charge kits. Secure
the accumulator safely to avoid sudden recoil movement in the unlikely event of
hose failure.
HAND PUMP can be mounted up to 3 m above reservoir oil level (at sea level altitude). If the
pressure gauge is fitted directly to the pump, protect it from accidental damage.
Apply ergonomic principles for easy handle operation.
FILTER should be mounted vertically with the bowl facing downwards to avoid excessive
oil spillage while replacing element.
START VALVE to be positioned for convenient actuation by the operator.
UNLOADING VALVE must be easily accessible for maintenance inspection.
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RELIEF VALVE should be mounted close to the accumulator oil end cap with no other valve or
component in between.
3.1.3 SYSTEM INSTALLATION

78
MOTOR with M10, M16, M22 and M28 starters the starter drive is supplied with the pinion
gear in the extended (engaged) position. The gear will retract after the first
start. Do not tamper with the starter drive assembly. To ensure the correct
engagement depth, turn the pinion gear counter-clockwise to extend the gear to
its utmost. Measure the distance from the motor mounting flange to the face of
the pinion gear. Deduct 13mm (1/2”) from that and the resultant value should
equal the bellhousing flange to ring gear distance (FRG). This should provide, in
the disengaged mode, a clearance between ring gear and pinion of approximately
6mm (1/4”). Apply marking blue on the gear teeth so that after the first start the
gear mesh can be inspected for accuracy. Clean flange faces to permit flush
mounting of the motor. Check for interference with engine parts and ring gear.
The pinion housing may be indexed in 90° increments (for M10, M16, M22, M28)
and 60° increments (for M38A, M66A) with respect to the starter motor housing.
ACCUMULATOR to be affixed securely with recommended Powerstart mounting brackets (part no.
AC-17).
HAND PUMP is to be mounted on a flat surface and shimmed if necessary to avoid body
distortion and ensure full movement of lever and handle. The pump handle may
not be left in the pump and must be stored separately.
FILTER is to be mounted on a flat surface, using the two M10 threaded holes in the filter
head. Make sure filter bowl faces down to minimise oil spillage during element
replacement.
RELIEF VALVE, unloading valve and accumulator pre-charge are factory pre-set and are not to be
tampered with.
HOSES and fittings have to be rated at 35 MPa (accumulator test pressure). Installation
has to be undertaken as per hose and fitting supplier’s specification and
recommendations. As a rule of thumb the bend radius should be 12 times the
nominal hose size. Avoid straight hose lines as the length can vary by ±3% when
pressurised. Remain within laminar velocity by avoiding erratic flow directional
changes. Between accumulator, start valve, motor and reservoir use only straight
adapters, through lines in T-pieces (if required) and 90° hose ends to attain
lowest flow restrictions.
Hose size for: M10, M16 M22, M28 M38A, M66A
Pressure Lines: 3/8” 1/2” 3/4”
Motor Return Lines: 1/2” 3/4” 1”
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INSTALLATION PARAMETERS
Pressure Suction, Gauge, Drain, Mounting

Model Ports Return line Pilot line Bolts Qty
Starter Motor M10, M16 3/8" NPT 3/8" NPT As per engine
Starter Motor M22, M28 3/8" NPT 1/2" NPT As per engine
Starter Motor M38, M66 SAE 12 SAE 12 As per engine
Port Adapters M38, M66 1/2" NPT 1-1/6" JIC
Accumulator ASC (10 TO 160) 3/4" NPT use AC-17 bracket 1 Set
Acc. Bracket AC-17 M10 or 3/8" 4
Handpump PH20 3/8" NPT 3/8" NPT 1/4" NPT M10 or 3/8" 4
Filter FP08 1/2" NPT M10 2
Footvalve VF 3/8" NPT M8 or 5/16" 2
Soft Start Valve SSV 3/4" NPT 1/4" NPT M8 or 5/16" 2
Relief valve VRH 3/4" NPT 1/2" NPT 1/4" NPT M8 or 5/16" 2
Unloading Valve VU-1 3/4" NPT 3/4" NPT 1/8" NPT M8 or 5/16" 2
Unloading Valve VU-4 SAE 16 SAE 16 1/8" NPT M8 or 5/16" 2
Reservoir RPH03 1/2" NPT M8 or 5/16" 4
Reservoir HSS10, HSS12 1/2" BSP M10 or 3/8" 4
Reservoir HSS30, HSS60 3/4" BSP M10 or 3/8" 4
3.1.4 COMMISSIONING OF SYSTEM

79
On prototypes and first off system installations, note the following for your records:
• Equipment compliance to the recommended specification.
• Equipment accessibility.
• Hose sizes and lengths.
3.1.5 PRIMING OF SYSTEM

80
• Fill reservoir with recommended mineral oil within ISO 32 to 46 (SUS 140 - 230).
• Actuate hand pump and expel air by loosening outlet connection on the pump. Retighten
connection.
• Bleed the system via the hand pump by loosening the fittings at the start valve inlet. Retighten all
fittings when oil escaping is free from air (no bubbles).
• Charge the system by means of the hand pump. Resistance will be built rapidly as the oil pressure
(shown on the pressure gauge) reaches the accumulator gas pre-charge pressure. This should
correspond with the pre-charge indicated on the accumulator nameplate. Continue pumping until the
system pressure of 21 MPa is reached.
• Check all connections for leaks. CAUTION: If any leaks are found do not attempt to tighten fittings
under pressure. Release pressure via the bleed screw on the hand pump. Once satisfied that no
pressure remains, replace thread sealant and/or tighten fitting and again pump by hand until the
system pressure is reached.
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3.1.6 STARTING PROCEDURE

81
• Ensure engine is in a serviceable condition (oil level, fuel supply, coolant, etc.). Fuel system must
be primed.
• 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.
• Activate starter valve.
• If engine fails to start, recharge accumulator with hand pump and repeat above step.
• Release starter valve as soon as the engine has started.
• Repeat the starting procedure a number of times to completely purge the system of air.
• If the 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.
On prototype installations record the return line backpressure approximately 50mm from the starter
motor outlet. Insert the pressure gauge on the T-piece branch line only. The backpressure must not
exceed 500 kPa (75 psi). Whilst cranking the engine take care to avoid personal injury.
Hydraulic starting systems require virtually no maintenance apart from replacing the filter element and a
periodic check of the gas precharge 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.
Provided that the above points are observed, a hydraulic starting system can be expected to give years
of trouble free life, but remember never try to overcome an engine or fuel problem by operating the
hydraulic starter above its design pressure (usually indicated by a red sector on the pressure gauge).
When having equipment repaired ensure that the work is 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.
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Maintenance
3.2 MAINTENANCE
19
To ensure economic and trouble free starting cycles, the basic preventative maintenance principles have
to be adhered to. If any problems arise during the routine checks please refer to “ Fejl! Ukendt X
argument for parameter. Fejl! Ukendt argument for parameter. “ on page 3-12 .
X X Undertake X X X
inspections when the machine is at ambient temperature to ensure correct pressure readings.
3.2.1 DAILY82
• Check system pressure at the pressure gauge which should read 21MPa (3000 psi) as standard
when the system is fully charged.
• As the system cools down it is normal for the pressure to drop slightly, however this should stabilise.
If it continues to drop inspect for leaks or refer to the troubleshooting guidelines on page 3-12 X
3.2.2 WEEKLY
83
• Check oil level, which should be at the low-level mark when accumulator is at system pressure. A
sudden drop of the oil level with no signs of external leakage in the system could indicate the loss of
the accumulator gas pre-charge pressure.
• Visually inspect all hydraulic connections and hoses for leaks and retighten if necessary. This
should never be done with the system under pressure. First release system pressure by loosening
the bleed screw on top of the hand pump. Once you are satisfied that no pressure remains,
retighten the fitting or replace the damaged hose or component. Retighten the bleed screw on the
hand pump. Pump the system up to 21 MPa (3000 psi). Inspect that the leak has been eliminated.
• In the unlikely event that a leak should develop between the motor body and port plate, retighten the
8 bolts for starter motors as follows:
M10, M16, M22, M28 to 12 Nm (8.8 lbf. ft)
M38A, M66A to 28 Nm (20.5 lbf. ft)
3.2.3 QUARTERLY
84
• Check accumulator pre-charge. This can be done as described in “ Fejl! Ukendt argument for X
parameter. Fejl! Ukendt argument for parameter. ” on page 3-7 . However, a far simpler method is
X X X X X
to shut the engine off, release system pressure via the bleed screw on top of the hand pump then
retighten the bleed screw and actuate the hand pump. The pressure will rapidly rise and then
stabilise. This pressure corresponds with the accumulator gas pre-charge. If, however, this pressure
rapidly rises to 21 MPa (3000 psi), it indicates that the accumulator has lost part or all of its gas
charge.
• To check the unloading valve integrity the engine has to be running. The cut out pressure of 21 MPa
is confirmed at the daily inspection (see above). Open the hand pump bleed screw to reduce the
system pressure slowly. Note the pressure reading as the mechanised pump starts to recharge the
starting system. This pressure should read between 16.8MPa (2400 psi) and 18.9 MPa (2700 psi)
depending on the recharge ratio 80% std. (90%optional). Retighten the bleed valve. The pressure
should rise to 21 MPa (3000 psi) at which point the valve should unload.
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Maintenance
3.2.4 SIX MONTHLY

85
Or every 2000 engine running hours (approximately 1500 starts) the filter element (part no: FP08-08-40)
has to be replaced. Very dusty environments may require more frequent replacement.
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Accumulator Gas Service
3.3 ACCUMULATOR GAS SERVICE

20
3.3.1 GENERAL
86
THE MACHINE MUST BE STOPPED, SWITCHED OFF AND ISOLATED PRIOR TO ANY ACTION
By turning the T-bar clockwise the adapter plunger moves forward lifting the gas valve poppet off the
seat, thereby opening a passage connecting the accumulator gas chamber to the outlet.
Pressure testing and recharging of accumulators must be undertaken with care and should be carried
out at ambient temperature. Refer to “ Fejl! Ukendt argument for parameter. Fejl! Ukendt argument
X X X
for parameter. ” on page 3-11 for a table showing the effect of different temperatures on the gas
X X X
precharge.
3.3.2 TESTING OF GAS PRE-CHARGE

87
NOTE: In order to obtain a correct reading, the accumulator should be at ambient temperature.
Furthermore, if the accumulator is connected up to a hydraulic system, all oil must first be discharged
from the accumulator. If the temperature exceeds 40°C (104°F) please refer to “ Fejl! Ukendt argument X
for parameter. Fejl! Ukendt argument for parameter. ” on page 3-11 .

X X X X X
• Clean the gas end cap of the accumulator by wiping all dirt away from around the gas valve
protector plug.
• Remove the gas valve protector plug, using a 6mm A/F allen key and clean the seal area, ensuring
that no dirt enters the threaded hole
• Screw in adapter ACGS-01 and hand tighten.
2nd Edition
R
• Turn T-bar of actuator ACGS-02 clockwise until it is fully retracted.

• Assemble actuator ACGS-02 onto adapter ACGS-01 and tighten lightly (17mm A/F spanner).
• Turn actuator T-bar clockwise to open the gas valve in the accumulator end cap.
• CAUTION: Excessive force used in tightening the T-bar will bend the actuator pin in the gas valve
and cause it to malfunction.
• If any pressure is present in the accumulator it will be registered on the gauge (PG63-25). If this
reading is substantially higher than the pre-charge pressure indicated on the accumulator label,
verify that all of the oil has been discharged from the accumulator. Also see note above if
temperature exceeds 40°C (104°F), prior to reducing pressure.
• Turn T-bar anti-clockwise until it is fully retracted.
• Unscrew actuator ACGS-02 from adapter ACGS-01 and remove adapter from accumulator.
• Inspect seal of gas valve protector plug and replace if necessary.
• Screw the gas valve protector plug into accumulator and tighten to 22 Nm (16 lbf. ft.).
3.3.3 GAS CHARGING PROCEDURE

88
WARNING: Only use dry nitrogen when charging hydraulic accumulators. The use of other gasses is
highly dangerous and could result in an explosion with the risk of serious personal injury or death.
If the standard nut ACCK-04 (3/4” BSPF) is not compatible with your nitrogen bottle connection, kindly
purchase the correct nut from your gas supplier. In order to obtain a correct reading, the accumulator
should be at ambient temperature. Furthermore, if the accumulator is connected up to a hydraulic
system, all oil must first be discharged from the accumulator. If the temperature exceeds 40°C (104°F)
please refer to “ Fejl! Ukendt argument for parameter. Fejl! Ukendt argument for parameter. ” on
X X X X
page 3-11 .
X X
• Clean the outlet of the nitrogen bottle before assembly. Connect the recharge valve to the nitrogen
bottle.
• Clean the gas end cap of the accumulator by wiping all dirt away from around the gas valve
protector plug.
• Remove the gas valve protector plug, using a 6mm allen key and clean the seal area, ensuring that
no dirt enters the threaded hole.
• Screw in adapter ACGS-01 and hand tighten.
• Turn actuator T-bar anti-clockwise until it is fully retracted.
• Assemble actuator ACGS-02 onto adapter ACGS-01, tightening lightly (17mm A/F spanner).
• Turn actuator T-bar clockwise to open the gas valve in the accumulator end cap.
• CAUTION: Excessive force used in tightening the T-bar will bend the actuator pin in the gas valve
and cause it to malfunction.
• If any pressure is present in the accumulator it will be registered on the gauge (PG63-25). If this
reading is substantially higher than the pre-charge pressure indicated on the accumulator label,
verify that all of the oil has been discharged from the accumulator. Also see note above if
temperature exceeds 40° (104°F), prior to reducing the pressure.
• To increase the pressure, slowly open the valve on the nitrogen bottle. Rapid filling of an
accumulator is undesirable since this causes heat to build up, resulting in incorrect readings.
2nd Edition
R
• When the desired pressure has been reached, close the gas valve on the nitrogen bottle. Allow the
temperature to stabilise for 3 - 4 minutes and check the pressure. If need be, adjust as dictated by
reading on the pressure gauge.
• To reduce the pressure, turn the bleed valve knob - see “ Fejl! Ukendt argument for parameter.
X X
Fejl! Ukendt argument for parameter. ” on page 5-6 , anti-clockwise for a short while, closing it
X X X X
every now and then to obtain a correct pressure reading.

• Ensure gas valve on the nitrogen bottle is closed.
• Turn T-bar on adapter ACGS-02 anti-clockwise until fully retracted.
• Release pressure trapped in hose by turning the bleed valve knob anti-clockwise.
• Unscrew actuator ACGS-02 from adapter ACGS-01 and remove adapter from accumulator.
• Inspect seal of gas valve protector plug and replace if necessary.
• Screw gas valve protector plug into accumulator and tighten to 22 Nm (16 lbf. ft.).
2nd Edition
R
Accumulator Gas Calculations
3.4 ACCUMULATOR GAS CALCULATIONS

21
3.4.1 ACCUMULATOR FLUID VOLUME CALCULATION

89
SYSTEM PRESSURE IN MPa

30 28 26 24 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
20 333 286 231 167 91 48 0
19 367 321 269 208 136 95 50 0
18 400 357 308 250 182 143 100 53 0
17 433 392 345 292 227 190 150 105 55 0
16 467 429 385 333 273 238 200 158 111 59 0
GAS PRECHARGE PRESSURE IN MPa
15 500 464 423 375 318 286 250 211 167 118 63 0
14 533 500 462 417 364 333 300 263 222 176 125 67 0
13 567 536 500 458 409 381 350 316 278 235 188 133 71 0
12 600 571 538 500 455 429 400 368 333 294 250 200 143 77 0
11 633 607 577 542 500 476 450 421 389 353 313 267 214 154 83 0
10 667 643 615 583 545 524 500 474 444 412 375 333 286 231 167 91 0
9 700 679 654 625 591 571 550 526 500 471 438 400 357 308 250 182 100 0
8 733 714 692 667 636 619 600 579 556 529 500 467 429 385 333 273 200 111 0
7 767 750 731 708 682 667 650 632 611 588 563 533 500 462 417 364 300 222 125 0
6 800 786 769 750 727 714 700 684 667 647 625 600 571 538 500 455 400 333 250 143 0
5 833 821 808 792 773 762 750 737 722 706 688 667 643 615 583 545 500 444 375 286 167
4 867 857 846 833 818 810 800 789 778 765 750 733 714 692 667 636 600 556 500 429 333
3 900 893 885 875 864 857 850 842 833 824 813 800 786 769 750 727 700 667 625 571 500
2 933 929 923 917 909 905 900 895 889 882 875 867 857 846 833 818 800 778 750 714 667
1 967 964 961 958 955 952 950 947 944 941 938 933 929 923 917 909 900 889 875 857 833
0.5 983 982 981 979 977 976 975 974 972 971 969 967 964 962 958 955 950 944 938 929 917
(Assuming isothermal gas expansion).
Note: The difference between the accumulator nominal volume and the available fluid volume must
never be less than 400cc.
AVAILABLE FLUID VOLUME = CHART VALUE x ACCUMULATOR NOMINAL VOLUME

(in cubic centimetres) (in litres)
98 Calculation Example
• Given: A starter system with a 5.5 ltr. accumulator pre-charged to 10 MPa and a system pressure of
21 MPa.
• Solution: At intersection of pre-charge pressure “10 MPa” and system pressure of “21 MPa”, the
selected chart value of “524“ is multiplied by the accumulator nominal volume of 5.5 ltr. to arrive at
the available fluid volume of 2882 cc.
2nd Edition
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Accumulator Gas Calculations
3.4.2 PRESSURE / TEMPERATURE COMPENSATION

90
Gas Temp Gas Pre-charge Pressure in MPa at 15°C

in °C 5 6 7 8 9 10 11 12 13 14 15
20 5,0 6,0 7,0 8,1 9,1 10,1 11,2 12,3 13,3 14,4 15,6
30 5,2 6,2 7,3 8,4 9,5 10,5 11,6 12,8 13,9 15,1 16,3
40 5,4 6,5 7,6 8,7 9,8 11,0 12,1 13,3 14,5 15,7 17,0
50 5,6 6,7 7,9 9,0 10,2 11,4 12,6 13,8 15,1 16,4 17,7
60 5,8 7,0 8,2 9,4 10,6 11,8 13,0 14,4 15,7 17,0 18,5
70 6,0 7,2 8,5 9,7 11,0 12,2 13,5 15,0 16,3 17,7 19,4
80 6,2 7,5 8,8 10,0 11,3 12,7 14,0 15,5 17,0 18,5 20,3
The above table shows, for example, that when an accumulator is recharged to 14 MPa whilst the
hydraulic oil is at a working temperature of 40°C and the oil temperature drops during the night to
ambient of 15°C, the accumulator pressure would have reduced by (15.7 - 14) = 1.7 MPa due to
contraction of the gas.
3.4.3 GAS PRESSURE LOSS

91
When checking the accumulator pressure with the Powerstart test kit ACTK, an inevitable slight loss of
pressure occurs. The approximate pre-charge pressure drop per test in percent equals 0.5 divided by
the accumulator nominal value. The use of a charging kit with a hose results in a far greater pressure
loss and is therefore not recommended.
PRESSURE LOSS = 0.5

(as a percentage of pre-charge pressure) ACCUMULATOR NOMINAL VOLUME (in litres)
99 Example
An accumulator with a nominal volume of 5.5 ltr. would lose 0.5 / 5.5 = 0,09% of pre-charge pressure for
each test. If the pre-charge pressure was 6500 kPa prior to testing, the pressure loss is 0.09% of 6500
kPa, i.e. 5.85 kPa. The remaining gas charge pressure would then be 6500 – 5.85 = 6494 kPa.
2nd Edition
R
Troubleshooting
3.5 TROUBLESHOOTING
22
Frequently system components are removed unnecessarily when in actual fact the problem for the
engine not starting lies elsewhere. If the engine turns at a fairly high speed (200 rpm plus) for a
reasonable period of time (3-5 seconds) and the engine does not start check the engine for fuel at the
injectors, faulty protection system, blocked air intake (filter or butterfly valve), correct compression, etc.
If the enclosed maintenance schedule is adhered to, any problems arising should be identified in time
and therefore avoid costly breakdowns.
Always ascertain that the correct equipment is installed (e.g. accumulator and motor size) and that the
test equipment, especially the pressure gauges, are in good working order. The equipment has been
inspected at installation and subsequent replacements must match the original parts.
3.5.1 ENGINE DOES NOT TURN

92
• Verify that system pressure is at 21 MPa (3000 psi).

• When the starter valve is actuated, observe if system pressure drops. If pressure is constant, it
indicates a seizure. This could be in the engine and caused by mechanical failure such as
overheating or hydraulic lock, either by a leaking cylinder head gasket or cracked cylinder head, or
by leaking fuel injectors. Refer to engine manufacturer’s handbook. If system pressure drops inspect
for leaks. If none are apparent, the failure is most likely within the starter motor. Remove the motor
and inspect the drive. If the pinion teeth are damaged inspect the engine ring gear for damage,
before rotating the engine to another position. Do not under any circumstances attempt to actuate
the starter either with it lying loose in the engine compartment or by holding it. The reactionary
torque is violent and damage to equipment or personal injury could result. In addition, the drive
spins at high speed and is unprotected when removed from the engine. Replace with a new motor
or one known to be in good working order.
• If the hydraulic accumulator has lost its gas charge. It is possible to build up full system pressure of
21 MPa (3000 psi) to check, release pressure by loosening the bleed screw on top of the hand
pump. Pressure will drop to zero immediately. Now retighten the bleed screw of the hand pump and
start pumping. After a few strokes of the hand pump, appreciable resistance will be felt, and the
pressure will immediately climb to 21 MPa (3000 psi). If this happens, replace the accumulator. In
multiple accumulator systems, each accumulator must be checked individually. (A short cranking
cycle indicates failure of one accumulator, refer to section 3.5.3 hereunder). X X
3.5.2 SLOW CRANKING OF ENGINE

93
If the cranking cycle is slow and extended indicating starter motor overload, check for engine problems
e.g. wrong lubricant viscosity, partial seizure of engine or excessive parasitic load which could be
caused by transmission or main hydraulic circuit failure (e.g. pump, off-loading valves, the failure of the
components driven by the engine including auxiliary hydraulic pumps, generators, etc.).
• Ensure hydraulic fluid viscosity is within ISO 32 to 46 (SUS 140-230).

• Inspect piping for correct sizes, refer to “ Fejl! Ukendt argument for parameter. Fejl! Ukendt
X X X
argument for parameter. ” on page 3-2 under “HOSES”. Check for hose damage, deformed hoses
X X X
or piping or obstructions inside the hoses. Occasionally the inner lining of the hose may collapse
and restrict the flow of oil.
2nd Edition
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Troubleshooting
• Ensure correct system pressure and pre-charge pressure as shown in test instructions “ Fejl! X
Ukendt argument for parameter. Fejl! Ukendt argument for parameter. ” on page 3-7 . As a
X X X X X
quick check, release system pressure at the hand pump bleed valve and retighten screw. Once the
hand pump is primed commence pumping by hand. The pressure indicated on the gauge should
increase rapidly until the accumulator gas pre-charge is reached after which the rise in pressure
should be gradual. If this pressure is higher or lower than 9 to 11 MPa refer to “ Fejl! Ukendt X
argument for parameter. Fejl! Ukendt argument for parameter. ” on page 3-8 . If the pressure
X X X X X
rises rapidly to 21 MPa (system pressure) it indicates that no gas charge is present at the
accumulator and the piston is "dead ended".
• Replace start valve with a new unit or one known to be in good working order.
3.5.3 SHORT STARTING CYCLE

94
• Ascertain correct accumulator and motor size.

• Test accumulator gas pre-charge as described in section 3.5.1 above in the last paragraph. If the
X X
system is equipped with more than one accumulator, refer to “ Fejl! Ukendt argument for X
parameter. Fejl! Ukendt argument for parameter. ” on page 3-7 .

X X X X X
• If the parasitic load is excessive, it can also cause a short cranking cycle. What happens is that
initially the full system pressure is sufficient to rotate the load, but as the pressure drops the output
torque of the starter drops to the point where it can no longer rotate the load. The starter then stalls,
resulting in a short cranking cycle. Refer to “ Fejl! Ukendt argument for parameter. Fejl! Ukendt
X X X
argument for parameter. ” above. X
• Replace starter with a new unit or one known to be in good working order.
3.5.4 PRESSURE LOSS (system will not hold pressure)

95
Visually inspect all system connections and piping for external leaks. If no external leaks are present,
this indicates leakage is taking place internally. It is a simple matter to isolate the faulty component. To
ensure the safety of the maintenance personnel the following tests must be carried out with the engine
shut off and system pressure at zero by loosening the bleed screw on top of the hand pump. After each
component has been tested, it is necessary to bleed off all pressure before removing the next line.
• Remove the return line from the starter motor to the reservoir. After the initial flow of oil, operate the
hand pump to build up 10 - 12 MPa (1500 – 1800 psi). If oil continues to flow from the motors return
line, replace the start valve. Reconnect the starter return line.
• If the system is equipped with an unloading valve disconnect the inlet from the engine driven pump,
the return/power-beyond line and the 1/4” external drain line if fitted. Operate the hand pump as
described in 2. above. If valve leaks replace it.
• Disconnect the return line from the relief valve to the reservoir. Powerstart relief valves are zero leak
valves. If valve leaks, replace it.
• If no leaks are detected after testing the above components, replace the hand pump. CAUTION: do
not attempt to test the hand pump since this must be done under pressure by trained personnel.
2nd Edition
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Troubleshooting
3.5.5 HAND PUMP MALFUNCTION

96
The hand pump is double acting and a correctly functioning hand pump must have a pumping action in
both directions viz. there should be very little free play in the pumping action.
• Check for mechanical wear in the link holes in both the pump plunger and pivot lever.
• Check for excessive wear between the pivot pin and pivot lever.
• Check for excessive wear between the pivot pin and pump body.
• Check for excessive wear between pump handle and pivot lever.
If excessive wear is present above replace the pump. If no signs of excessive wear are detected and
pump action feels sloppy, proceed as follows:
Pull the handle rapidly in one direction for its full travel and observe if handle tends to spring back. If it
does, repeat above procedure and pause for a few seconds at the end of the stroke. If the pump no
longer springs back, this indicates a restriction in the supply line to the pump, which must be cleared. If
pump handle continues to spring all the way back, this indicates a malfunctioning suction valve which
could either be contaminated or damaged. If handle is loose in both directions, this indicates the delivery
valve is contaminated or damaged. A contaminated oil reservoir will cause a pump to malfunction and
should be drained, flushed and refilled with clean oil. If pumping action is “spongy“, this indicates air in
the system. Check oil level and ensure that there are no suction leaks.
3.5.6 GENERAL
97
If fluid emerges from the reservoir during cranking, check that it has not been overfilled. Powerstart
reservoirs have been sized so as not to overflow if the reservoir is filled up to the upper mark of the level
gauge whilst the accumulators are empty. Another reason for oil emerging from the top of the reservoir
during cranking could be a reservoir manufactured by a third party where no baffle plate has been
provided or where the return connection is situated in close proximity to the breather cap. It is
recommended that horizontal baffle plates be fitted to small capacity reservoirs, with ports below the
baffle.
If there are signs of oil inside a dry fly wheel housing, remove the starter motor and inspect for leakage
from the shaft seal before stripping the flywheel housing.
If the starter motor appears to leak between the pinion housing and the starter or at the starter motor
nameplate, check if the flywheel housing is a wet housing. This is common on forklift trucks, and the
problem can be overcome by sealing the pinion housing to starter face and nameplate to starter face
with a silicone sealer. Use a conventional gasket between the starter motor and flywheel mounting face.
IF THE ABOVE GUIDELINES HAVE NOT RESOLVED THE PROBLEM PLEASE CALL
POWERSTART OR THEIR DISTRIBUTOR FOR FURTHER ASSISTANCE
2nd Edition
R
Warranty Claim Form
WARRANTY CLAIM FORM
3.6General
WARRANTY CLAIM FORM
23
Customer: Date:
Contact person:
Tel. No.: Fax. No.:
Distributor:
Installation Details
Starter: Serial no.:
Engine: Installation date:
No. of starts: Failure date:
Parasitic load (Nm):
Installed by:
Failure Details:
Failed components:
Remarks:
For internal use only:
Claim assessed by: Accepted/rejected:
Repair/supply new: Job no. or inv. no.:
Cause of failure/remarks:
2nd Edition
Accessories
R
Reservoir Specifications
4. ACCESSORIES
3
4.1 PRESSURE GAUGE SPECIFICATIONS

24
1 00 Part number:
PG63-25
1 01 Features:
• Glycerine filled casing.
• Plexiglass safety front.
• Snubber screw.
• Safety blow out plug.
1 02 Specifications:
Weight 325 gram
Construction One piece forged brass case and stem
Working pressure 0 – 25 MPa
Temperature range Ambient -20°C to +60°C (-4°F to +140°F)
Fluid media -20°C to +100°C (-4°F to +212°F)
2nd Edition
Accessories
R
Reservoir Specifications
4.2 RESERVOIR SPECIFICATIONS

25
1 03 Part number:
As per table below
1 04 Features:
• Heavy gauge steel welded construction
• All ports can be used for either suction or return
• Level gauge
• Filler breather including strainer
• Horizontal baffle plate to prevent splashing and foaming Nominal Usable
Capacity
Model A B C D E F Ports ltr. USG Weight
HSS 10L 280 205 215 295 215 255 1/2" BSP 10 2.6 8.5 kg
HSS 12L 285 220 215 295 215 255 1/2" BSP 12 3.2 8.8 kg
HSS 30L 465 300 230 310 395 270 3/4" BSP 30 7.9 12.5 kg
HSS 60L 620 330 305 385 555 345 3/4" BSP 60 15.8 20 kg
2nd Edition
Accumulators
R
Accumulator Specifications
5. ACCUMULATORS
4
5.1 ACCUMULATOR SPECIFICATIONS

26
1 05 Features:
• During severe over pressurisation seals extrude to vent gas pressure prior to structural failure.
• End cap retention design prevents disassembly if accumulator is pressurised.
• Protector plug quick exhaust slot safeguards operator during disassembly in the unlikely event of the
valve core failing.
• Pre-charge valve is protected from damage.
• Unique T-seal cannot roll.
• Accumulators conform to BS5500 1988 ASME viii division 2 1986
Construction Certified steel tube - seamless to din 2391 (part 2)
Working pressure 21 MPa (3000 psi)
Test pressure 35 MPa (5000 psi)
Average burst pressure 120 MPa (20000 psi)
Safety ratio In excess of 4:1
Fluid media Mineral oil
Viscosity range ISO 32 to 46 (SUS 140 to 230)
Temperature range -30°C to +100°C (-22°F to +212°F)
Seals Nitrile (std.)
Gas valve assembly Stainless steel tamper resistant
Gas seal Twin - bubble tight
Capacity Length "L" Mass Capacity Length "L" Mass

Model Model
ltr. USG mm in. kg lbs. ltr. USG mm in. kg lbs.
A010SC 1.0 0.25 230 9.0 15.5 34 A100SC 10.0 2.60 965 38.0 40.5 89
A025SC 2.5 0.66 350 13.8 19.5 43 A120SC 12.0 3.20 1125 44.0 46.0 101
A040SC 4.0 1.06 475 18.7 24.0 53 A160SC 16.0 4.20 1450 57.0 57.0 125
A055SC 5.5 1.50 600 24.0 28.0 62
2nd Edition
Accumulators
R
Lloyds Approval Certificate
5.2 LLOYD’S APPROVAL CERTIFICATE

27
2nd Edition
Accumulators
R
Accumulator Parts List
5.3 ACCUMULATOR PARTS LIST

28
Item Description Qty Part no.

Gas volume
1 Barrel 1 AC-01-
010 - 1.0 ltr.
2 Piston 1 AC-02
025 - 2.5 ltr.
3 Oil end cap 1 AC-03 -
040 - 4.0 ltr.
4 Gas end cap 1 AC-04
055 - 5.5 ltr.
5 Retaining ring (set) 2 AC-05 100 - 10.0 ltr.
6 Retaining washer 2 AC-06 120 - 12.0 ltr.
7 Retaining bolt 2 AC-07 160 - 16.0 ltr.
8 Nameplate 1 AC-08
9 Screw 1 AC-09
10 Gas plug 1 AC-10
11 Valve core 1 AC-11 Fluid connection
12 Piston seal (including backup) 1 AC-12 1 - ¾” NPT
13 Wear strip 2 AC-13 2 - 1” NPT
14 O-ring (endcap) 2 AC-14 3 - 1 ¼” NPT
15 Backup ring (endcap) 2 AC-15 4 - ¾” BSPF
16 Plug seal 1 AC-16 5 - 1” BSPF
6 - 1 ¾” BSPF
Seal kit includes items 12 - 16 AC-SK
2nd Edition
Accumulators
R
Accumulator Bracket
5.4 ACCUMULATOR BRACKET

29
1 07 Part number:
AC-17
Weight 1.1 kg each
Construction Steel zinc plated and passivated
Clamp size 145mm Diameter tube

1 Base 2 AC-17-1
2 Clamp 2 AC-17-2
3 Bolt 4 AC-17-3
2nd Edition
Accumulators
R
Accumulator Test Kit
5.5 ACCUMULATOR TEST KIT

30
1 09 Part number:
ACTK
1 10 Features:
• Compact light weight glycerine filled gauge
• Adapter 1 is of stainless steel
• Design minimises gas loss when checking pre-charge pressure
• One piece forged brass gauge and stem

1 Adaptor 1 ACGS-01
2 Actuator 1 ACGS-02
3 Elbow 1 ACTK-01
4 Reducer 1 ACTK-02
5 Pressure gauge 1 PG63-25
6 Seal 1 ACGS-01-3
2nd Edition
Accumulators
R
Accumulator Charge Kit
5.6 ACCUMULATOR CHARGE KIT

31
1 11 Part number:
ACCK
1 12 Features:
• Glycerine filled gauge
• Gauge mounted on gas bottle is less subject to
damage/abuse
• Item 5 incorporates sintered metal filter
• Adapter 1 is of stainless steel
• One piece forged brass gauge case and stem
• 3/4" BSPF thread to fit standard nitrogen bottles

1 Adaptor 1 ACGS-01
2 Actuator 1 ACGS-02
3 Hose 1 ACCK-01
4 Pre-charge valve 1 ACCK-02
5 Valve adapter 1 ACCK-03
6 Nut 1 ACCK-04
7 Elbow 1 ACCK-05
9 Seal 1 ACGS-01-3
2nd Edition
Starter drive
R
Starter Drive Specifications
6. STARTER DRIVE
5
6.1 STARTER DRIVE SPECIFICATIONS

32
1 13 Part number:
See “ Fejl! Ukendt argument for parameter. ” on page 12-5
X X X
1 14 Features:
• Robust construction
• Repairable
• Non-sparking, beryllium copper pinions available in marinised anti-corrosion option
Weight 1.43kg
Construction Alloy steel
Speed range 0-7000 rpm
Rotation CW (standard)
CCW (optional)
Pinion options See data sheet on page 12-5 X
2nd Edition
Starter drive
R
Starter Drive Parts List
6.2 STARTER DRIVE PARTS LIST

33
Item Description Qty Part no. Item Description Qty Part no.
1 Drive washer 1 M22-23-01 10 Detent spring 1 M22-23-10
2 Spindle 1 M22-23-02 11 Plunger 2 M22-23-11
3 Torsion spring 1 M22-23-03 12 Helix nut 1 M22-23-12
4 Thrust washer 1 M22-23-04 13 Helix shaft 1 M22-23-13
5 Clutch 1 M22-23-05 14 Thrust washer 1 M22-23-14
6 Retaining ring 1 M22-23-06 15 Bevel washer 1 M22-23-15
7 Retaining ring 1 M22-23-07 16 Stop ring 1 M22-23-16
8 Plug 2 M22-23-08 17 Locating screw 1 M22-23-17
9 Anti-drift spring 1 M22-23-09
2nd Edition
Filters
R
Pressure Filter Specifications
7. FILTERS
6
7.1 PRESSURE FILTER SPECIFICATIONS

34
1 16 Part number:
FP08
1 17 Features:
• Bypass valve
• Mounting holes provided
• Plug bonded to filter element
• Valve components retained during disassembly
Weight 3.2kg
Construction All steel (ferro blackened)
Maximum working pressure 21 MPa (3000 psi)
Viscosity range ISO 32 to 46 (SUS 140-230)
Flow rates 80 l/min (21 usgpm) at 40 micron
50 l/min (13 usgpm) at 5 & 10 micron
Bypass cracking press. 750 kPa
Warning: Drop system pressure to zero before replacing filter element. Only hand tighten filter body.
2nd Edition
Filters
R
Pressure Filter Parts List
7.2 PRESSURE FILTER PARTS LIST

35

1 Filter head 1 FP08-01
2 Filter body 1 FP08-02
3 Standpipe 1 FP08-03
4 Poppet 1 FP08-04
5 Spring 1 FP08-05
6 O-ring (body) 1 FP08-06
7 O-ring (standpipe) 1 FP08-07
8 Filter element 40 micron (standard) 1 FP08-08-40
8a Filter element 10 micron (optional) FP08-08-10
8b Filter element 5 micron (optional) FP08-08-05
9 Nameplate (not illustrated) 1 FP08-09
10 Warning lable (not illustrated) 1 FP08-10
11 Mounting rivets (not illustrated) 4 FP08-11
2nd Edition
Motors
R
M10 to M66A Motor Specifications and Dimension Table
8. MOTORS
7
8.1 M10 TO M66A MOTOR SPECIFICATIONS & DIMENSION TABLE

36
M10 M16 M22 M28 M38 M66

Weight 9.5 kg 11 kg 21.5kg
Construction Cast iron
Max. working press. 21 MPa (3000 PSI)
Speed range 0-7000 rpm 0-4500 rpm
Rotation CW - Standard (CCW - Optional)
Duty cycle Intermittent
Overall volumetric efficiency 92% (minimum)
9.98cc 15.59cc 22.1 cc 28 cc 38 cc 66 cc
Displacement
(0.6 cu.in.) (0.95 cu.in) (1.35 cu.in.) (1.71 cu.in.) (2.32 cu.in.) (4 cu.in.)
Max. torque at 21 MPa 30 Nm 48 Nm 66 Nm 84 Nm 124 Nm 216 Nm
(3000 psi) (22 lbf.ft.) (35 lbf.ft.) (49 lbf.ft.) (62 lbf.ft.) (92 lbf.ft.) (160 lbf.ft.)
Overall length A 293 328.5 435

Motor length B 180 215.5 295
Dimensions in mm)
Motor diameter C 89.5 101.5 130

Dist. between ports D 41.3 47.6 65
Inlet port E 3/8" NPT 3/8" NPT SAE 12
Outlet port F 3/8" NPT 1/2" NPT SAE 12
Flange thickness G 21
Pinion hsg. Length H 113
Depends upon configuration
Mounting flange SAE 3
Flange to ring gear (FRG) 50.8 (2")
1 19 Part number:
See “ Fejl! Ukendt argument for parameter. ” on page 12-2
X X X
1 20 Features:
• Light weight yet aluminium free.
• Rugged, long life construction.
• Reduced internal case pressure.
• Improved seal design.
• Non-sparking, beryllium copper drives and marinised anti-corrosion models available.
2nd Edition
Motors
R
M10 to M28 Motor Dimensions
8.2 M10 TO M28 MOTOR DIMENSIONS

37
• For clockwise rotation orientate port plate as

shown.
• For counter clockwise rotation, orientate port

plate 180° and ensure that CCW drive is used.
For model variations see “ Fejl! Ukendt argument

X
for parameter. ” on page 12-2 .

X X X
2nd Edition
Motors
R
M10 to M28 Motor Dimensions
8.3 M38A TO M66A MOTOR DIMENSIONS

38
• For clockwise rotation orientate port plate as

shown.
• For counter clockwise rotation, orientate port

plate 180° and ensure that CCW drive is used.
For model variations see “ Fejl! Ukendt argument

X
for parameter. ” on page 12-2 .

X X X
2nd Edition
Motors
R
M10 and M16 Motor Parts List
8.4 M10 AND M16 MOTOR PARTS LIST

39
1 Motor housing 1 M10-01 15 O-ring (seal) 1 M22-15
2 Port plate 1 M10-02 16 Shaft seal 1 M22-16
3 Shaft 1 M10-03 17 Key 1 M22-17
4 Barrel 1 M10-04 18 Locating screw 1 M10-18
5 Piston 7 M10-05 19 Nameplate 1 M22-19
6 Spring 1 M10-06 20 Screw 2 M22-20
7 Circlip (barrel) 1 M10-07 21 Bolt 8 M10-21
8 Thrust bearing 1 M10-08 22 Drive (excl. 23 and 24) 1 M08-23
9 Centre bearing 1 M10-09 23 Circlip (gear) 1 M08-24
10 Bearing (port plate) 1 M10-10 24 Pinion gear 1 M08-25-
11 Seal holder 1 M22-11 25 Drive assembly 1 M08-B-
12 Circlip (bearing) 1 M22-12 26 Pinion housing 1 M22-H
13 Circlip (holder) 1 M22-13 27 Bolt (not illustrated) 4 M22-28-
14 O-ring (holder) 1 M22-14 28 Bearing (pinion hsg.) 1 M22-10
Motor size See ordering code on section

Items 11-17 and 28 included in seal kit M22-SK
10 or 16 Fejl! Ukendt argument for
Items 22-24 comprise drive assembly
2nd Edition
Motors
R
M22 and M28 Motor Parts List
8.5 M22 AND M28 MOTOR PARTS LIST

40
3 Shaft 1 M22-03 17 Key 1 M22-17
4 Barrel 1 M-04 18 Locating screw 1 M22-18
5 Piston 7 M-05 19 Nameplate 1 M22-19
6 Spring 1 M22-06 20 Screw 2 M22-20
7 Circlip (barrel) 1 M22-07 21 Bolt 8 M22-21
8 Thrust bearing 1 M22-08 22 Drive (excl. 23 and 24) 1 M22-23
9 Centre bearing 1 M22-09 23 Circlip (gear) 1 M22-24
10 Bearing (port plate) 1 M22-10 24 Pinion gear 1 M22-25-
11 Seal holder 1 M22-11 25 Drive assembly 1 M22-B-
12 Circlip (bearing) 1 M22-12 26 Pinion housing 1 M22-H
13 Circlip (holder) 1 M22-13 27 Bolt (not illustrated) 4 M22-28-
14 O-ring (holder) 1 M22-14 28 Bearing (pinion hsg.) 1 M22-10
Motor size See ordering code on section

Items 11-17 and 28 included in seal kit M22-SK
22 or 28 Fejl! Ukendt argument for
Items 22-24 comprise drive assembly
2nd Edition
Motors
R
M66A Motor Parts List
8.6 M38A MOTOR PARTS LIST

41
3 Shaft 1 M38A-03 17 Nameplate 1 M22-19
4 Barrel 1 M66-04 18 Screw 2 M22-20
5 Piston 7 M66-05 19 Bolt 8 M66-21
6 Spring 1 M66-06 20 Drive assembly 1 M38A-B
7 Circlip (barrel) 1 M66-07 21 Pinion housing 1 M38A-H3S
8 Thrust bearing 1 M66-08 22 Bolt (not illustrated) 6 M66-28
9 Centre bearing 1 M66-09 23 Bearing (pinion hsg.) 1 M38A-29
66 Bearing (port plate) 1 M66-66 24 Displacement insert 1 M66-30
11 Seal holder 1 M66-11 25 Spring pin 1 M66-31
12 Circlip (bearing) 1 M66-12 26 Circlip (insert) 1 M66-32
13 Circlip (holder) 1 M66-13 27 Washer (barrel) 1 M66-33
14 O-ring (holder) 1 M66-14
28 Inlet reducer 1 M66-40
Port adaptors not shown 29 Outlet adaptor 1 M66-41
See ordering code on section
Fejl! Ukendt argument for
2nd Edition
Motors
R
M66A Motor Parts List
8.7 M66A MOTOR PARTS LIST

42
3 Shaft 1 M38A-03 17 Nameplate 1 M22-19
4 Barrel 1 M66-04 18 Screw 2 M22-20
5 Piston 7 M66-05 19 Bolt 8 M66-21
6 Spring 1 M66-06 20 Drive assembly 1 M38A-B
7 Circlip (barrel) 1 M66-07 21 Pinion housing 1 M38A-H3S
8 Thrust bearing 1 M66-08 22 Bolt (not illustrated) 6 M66-28
9 Centre bearing 1 M66-09 23 Bearing (pinion hsg.) 1 M38A-29
66 Bearing (port plate) 1 M66-66 24 Displacement insert 1 M66-30
11 Seal holder 1 M66-11 25 Spring pin 1 M66-31
12 Circlip (bearing) 1 M66-12 26 Circlip (insert) 1 M66-32
13 Circlip (holder) 1 M66-13 27 Washer (barrel) 1 M66-33
14 O-ring (holder) 1 M66-14
28 Inlet reducer 1 M66-40
Optional port adaptors not shown 29 Outlet adaptor 1 M66-41
See ordering code on section
Fejl! Ukendt argument for
2nd Edition
Hand Operated Pumps
R
PH20 Handpump Specifications
9. HAND OPERATED PUMPS

8
9.1 HANDPUMP SPECIFICATIONS

43
1 21 Part number:
PH20
1 22 Features:
• Bleed screw is tamper resistant
• Bronze piston bush
• Pivot pin hardened and ground
• Piston rod heat treated stainless steel
Weight without handle 4.5kg
Weight including handle 6.7kg
Construction Cast iron
Maximum working pressure 21MPa (3000 psi)
Suction pressure 75 kPa (12 psi) absolute*
Temperature range -30°C to +100°C
(-22°F to +212°F)
Displacement 20 cc/cycle (1.22 cu.in.)
Force on handle 210N (48 lbf.) at 21 MPa
Bypass Manual
Bottom inlet for tank top mounting
* This equates to the pump operating (priming) 3m above oil

level at sea level altitude.
2nd Edition
Hand Operated Pumps
R
PH20 Handpump Parts List
9.2 HANDPUMP PARTS LIST

44
1 Pump body 1 PH20-01 17 Valve spring 2 PH20-17
2 Guide bush 1 PH20-02 18 Circlip (piston bush) 1 PH20-18
3 Bleed screw 1 PH20-03 19 O-ring (guide bush) 1 PH20-19
4 Bleed plug 1 PH20-04 20 O-ring (bleed screw) 1 PH20-20
5 Tank top plug 1 PH20-05 21 Seal (outlet valve seat) 1 PH20-21
6 Pivot lever 1 PH20-06 22 O-ring (piston) 1 PH20-22
7 Handle 1 PH20-07 23 Backup ring (piston) 1 PH20-23
8 Pivot pin 1 PH20-08 24 O-ring (bush) 1 PH20-24
9 Circlip 2 PH20-09 25 Backup ring (bush) 1 PH20-25
10 Connecting link 1 PH20-10 26 O-ring (plunger) 1 PH20-26
11 Piston bush 1 PH20-11 27 Backup ring (plunger) 1 PH20-27
12 Piston 1 PH20-12 28 Seal ring 1 PH20-28
13 Outlet valve seat 1 PH20-13 29 Seal ring 1 PH20-29
14 Inlet valve seat 1 PH20-14 30 Standpipe 1 PH20-30
15 Inlet spring retainer 1 PH20-15 31 O-ring (standpipe) 1 PH20-31
16 Valve ball 2 PH20-16 32 Plug 1 PH20-32
Items 18 to 27 inluded in seal kit PH20-SK

2nd Edition
Starting Valves
R
Footvalve Specifications
10. STARTING VALVES

9
10.1 FOOTVALVE SPECIFICATIONS

45
1 24 Part number:
VF
1 25 Features:
• Wiper seal
• Extended guide bush
• Safety plug gives access to bore of valve spool
Weight 1.5kg
Construction Body and knob - cast iron
Spool - stainless steel (heat treated)
Spring Cadmium plated
Maximum working pressure 21 MPa (3000 psi)
Flow rate (max.) 75 l/min (20 usgpm)
Force to open 270N (60 lbf.) at 21 MPa (3000 psi)
2nd Edition
Starting Valves
R
Footvalve Parts List
10.2 FOOTVALVE PARTS LIST

46

1 Valve body 1 VF-01
2 Valve spool 1 VF-02
3 Knob 1 VF-03
4 Plug 1 VF-04
5 Spring 1 VF-05
6 O-ring 3 VF-06
7 Wiper seal 1 VF-07
8 Lock pin 1 VF-08
2nd Edition
Starting Valves
R
Cable Operated SSV Specifications
10.3 CABLE OPERATED SOFT START VALVE SPECIFICATIONS

47
1 27 Part number:
SSVC
1 28 Features:
• SSVC valves provide progressive pinion engagement
with ring gear resulting in extended bearing and
pinion gear life (no shock loads).
• Ideal for beryllium copper pinions.
• Optional engine interlock prevents engagement with
rotating flywheel.
• Optional transmission interlock prevents starting on
mobile machinery unless vehicle is in neutral.
Weight 3.2kg
Construction Body - cast iron
Lever - Stainless steel
Flow rate 150 l/min (40 usgpm)
2nd Edition
Starting Valves
R
Cable Operated SSV Parts List
10.4 CABLE OPERATED SOFT START VALVE PARTS LIST

48
1 Valve body 1 SSV-01 16 Restrictor clip 1 SSV-17
2 Spool 1 SSV-02 17 Bellows 1 SSV-18
3 Spring retainer 1 SSV-03 18 Seal retainer 1 SSV-19
4 Seat 1 SSV-04 19 Ball 1 SSV-25
5 Spacer 1 SSV-05 20 Retaining bush 1 SSV-31
6 Pilot housing 1 SSV-06 21 Lever 1 SSV-32
7 Spring 1 SSV-07 22 Plunger 1 SSV-33
8 Auxiliary plug 1 SSV-08 23 Cable pin 1 SSV-34
9 Plug 2 SSV-09 24 Spring 1 SSV-35
10 O-ring 1 SSV-10 25 Circlip 1 SSV-36
11 O-ring 1 SSV-11 26 Screw 1 SSV-37
12 O-ring 1 SSV-12 27 Nut 1 SSV-38
13 O-ring 1 SSV-13 28 O-ring 1 SSV-77
14 Glydring 1 SSV-14 29 Plug 1 SSV-75
15 Pin 1 SSV-15
2nd Edition
Starting Valves
R
Manually Operated SSV Specifications
10.5 MANUALLY OPERATED SOFT START VALVE SPECIFICATIONS

49
1 30 Part number:
SSVM
1 31 Features:
• SSVM valves provide progressive pinion engagement
rotating flywheel.
Weight 3.2kg
Spool - Stainless steel
2nd Edition
Starting Valves
R
Manually Operated SSV Parts List
10.6 MANUALLY OPERATED SOFT START VALVE PARTS LIST

50
1 Valve body 1 SSV-01 15 Pin 1 SSV-15
2 Spool 1 SSV-02 16 Restrictor clip 1 SSV-17
3 Spring retainer 1 SSV-03 17 Bellows 1 SSV-18
4 Seat 1 SSV-04 18 Seal retainer 1 SSV-19
6 Pilot housing 1 SSV-06 20 Plunger 1 SSV-22
7 Spring 1 SSV-07 21 Spring 1 SSV-23
8 Auxiliary plug 1 SSV-08 22 Knob 1 SSV-24
9 Plug 2 SSV-09 23 Ball 1 SSV-25
10 O-ring 1 SSV-10 24 Spring pin 1 SSV-26
11 O-ring 1 SSV-11 25 Wiper seal 1 SSV-27
13 O-ring 1 SSV-13 27 Plug 1 SSV-75
14 Glydring 1 SSV-14
2nd Edition
Starting Valves
R
Pilot Operated SSV Specifications
10.7 PILOT OPERATED SOFT START VALVE SPECIFICATIONS

51
1 33 Part number:
SSVP
1 34 Features:
• SSVP valves provide progressive pinion engagement
rotating flywheel.
• Provides reliable remote control in corrosive
environments via ¾” pilot hose.
Weight 3.2kg
2nd Edition
Starting Valves
R
Pilot Operated SSV Parts List
10.8 PILOT OPERATED SOFT START VALVE PARTS LIST

52
1 Valve body 1 SSV-01 11 O-ring 1 SSV-12
2 Spool 1 SSV-02 12 O-ring 1 SSV-13
3 Spring retainer 1 SSV-03 13 Glydring 1 SSV-14
4 Seat 1 SSV-04 14 Pin 1 SSV-15
5 Spacer 1 SSV-05 15 Restrictor clip 1 SSV-17
6 Pilot housing 1 SSV-06 16 Retaining bush 1 SSV-41
7 Spring 1 SSV-07 17 Seal retainer 1 SSV-42
8 Auxiliary plug 1 SSV-08 18 Plug 1 SSV-75
2nd Edition
Starting Valves
R
Solenoid Operated SSV Specifications
10.9 SOLENOID OPERATED SOFT START VALVE SPECIFICATIONS

53
1 36 Part number:
SSVS
1 37 Features:
• SSVS valves provide progressive pinion engagement
rotating flywheel.
• Transmission interlock prevents starting on mobile
machinery unless vehicle is in neutral.
• Provides convenient remote control.
• Robust zinc plated shell covers encapsulated coil.
Weight 3.7kg
Spool - Stainless steel
Operating voltage 24VDC standard, other voltages on request
Current draw 10A Maximum
2nd Edition
Starting Valves
R
Solenoid Operated SSV Parts List
10.10 SOLENOID OPERATED SOFT START VALE PARTS LIST

54
1 Valve body 1 SSV-01 16 Restrictor clip 1 SSV-17
2 Spool 1 SSV-02 17 Seal retainer 1 SSV-19
3 Spring retainer 1 SSV-03 18 Spring 1 SSV-23
4 Seat 1 SSV-04 19 Ball 1 SSV-25
6 Pilot housing 1 SSV-06 21 Plunger 1 SSV-52
7 Spring 1 SSV-07 22 Sleeve 1 SSV-53
8 Auxiliary plug 1 SSV-08 23 Override button 1 SSV-54
9 Plug 2 SSV-09 24 Actuator assembly 1 SSV-55
10 O-ring 1 SSV-10 25 Coil 1 SSV-56
11 O-ring 1 SSV-11 26 Lock nut 1 SSV-57
14 Glydring 1 SSV-14 29 Plug 1 SSV-75
15 Pin 1 SSV-15
2nd Edition
Starting Valves
R
Manually Operated Pilot Valve Specifications
10.11 MANUALLY OPERATED PILOT VALVE SPECIFICATIONS

55
1 39 Part number:
VPMP
1 40 Features:
• Zero internal leakage.
Weight 0.3kg
Construction All steel
Pulling force to open 70N (16 lbf.)
2nd Edition
Pressure Control Valves
R
Relief Valve Specifications
11. PRESSURE CONTROL VALVES

10
11.1 RELIEF VALVE SPECIFICATIONS

56
1 42 Part number:
VRH21
1 43 Features:
• Tamper resistant.
Weight 2.4 kg
Maximum working pressure 23MPa (3300 psi) factory preset
Other settings available on request
2nd Edition
R
Unloading Valve Specifications
11.2 UNLOADING VALVE SPECIFICATIONS

57
Dimensions (mm) Flow (l/min.) Flow (usgpm) Ordering Code

Model no.
A B C D Ports Min. Max. Min. Max.
VU-1 95 89 38 70 3/4" NPT 16 130 4.25 35
VU – – -
VU-4 101 98 45 70 SAE 16 75 225 20 60
1 45 Features:
Size
• Power beyond option available. 1 - ¾” NPT
4 - SAE 16
1 46 Specifications: Drain
I - Internal
Weight 2.0kg (VU-1),2.5kg (VU-4) E - External
Maximum working pressure 21MPa (3000 psi) Unloading Pressure (MPa)
Fluid media Mineral oil (Factory preset)
Viscosity range ISO 32 to 46 21 - Start system
(SUS 140-230) 14 - Brake circuit
Temperature range -30°C to +100°C
Pressure Differential
(-22°F to +212°F)
Pressure ratio 80% standard 80 - 80%
90 - 90%
(loading to unloading) 90% optional
If pump is dedicated to starting system, specify internal drain to simplify piping (eg. VU-1-I-21-80). If return port is
to feed and auxiliary circuit (power beyond) specify external drain (eg. VU-1-E-14-90).
Caution: If pump is below minimum flow rate specified the valve might malfunction and operate as a relief valve
instead, causing the system to overheat.
2nd Edition
R
Unloading Valve VU-1 Parts List
11.3 UNLOADING VALVE VU-1 PARTS LIST

58
1 Valve body 1 VU-101 12 O-ring 2 VU-012
Head (external drain) 1 VU-002-E 13 Ball 1 VU-013
2
Head (internal drain) 1 VU-002-I Screw (13 to 21 MPa) 1 VU-014-21
14
3 Check valve assembly 1 VU-103 Screw (5.5 to 13MPa) 1 VU-014-13
4 O-ring 2 VU-004 15 Adjuster plug 1 VU-015
5 O-ring 1 VU-105 16 Seal holder 1 VU-016
6 Main poppet 1 VU-106 17 O-ring 1 VU-017
7 Poppet spring 1 VU-107 Spring (13 to 21 MPa) 1 VU-018-21
18
8 Circlip 1 VU-108 Spring (5.5 to 13 MPa) 1 VU-018-13
9 Plug 1 VU-009 19 Piston 1 VU-019
10 O-ring 1 VU-010 20 Bolt (not illustrated) 4 VU-020
Cartridge - 80% 1 VU-011-80 21 Lock nut 1 VU-021
11
Cartridge - 90% 1 VU-011-90 22 O-ring (for int. drain) 1 VU-022
2nd Edition
R
Unloading Valve VU-4 Parts List
11.4 UNLOADING VALVE VU-4 PARTS LIST

59
1 Valve body 1 VU-401 12 O-ring 2 VU-012
Head (external drain) 1 VU-002-E 13 Ball 1 VU-013
2
Head (internal drain) 1 VU-002-I Screw (13 to 21 MPa) 1 VU-014-21
14
3 Check valve assembly 1 VU-403 Screw (5.5 to 13MPa) 1 VU-014-13
4 O-ring 2 VU-004 15 Adjuster plug 1 VU-015
5 O-ring 1 VU-405 16 Seal holder 1 VU-016
6 Main poppet 1 VU-406 17 O-ring 1 VU-017
7 Poppet spring 1 VU-407 Spring (13 to 21 MPa) 1 VU-018-21
18
8 Circlip 1 VU-408 Spring (5.5 to 13 MPa) 1 VU-018-13
9 Plug 1 VU-009 19 Piston 1 VU-019
10 O-ring 1 VU-010 20 Bolt (not illustrated) 4 VU-020
Cartridge - 80% 1 VU-011-80 21 Lock nut 1 VU-021
11
Cartridge - 90% 1 VU-011-90 22 O-ring (for int. drain) 1 VU-022
2nd Edition
Accumulator, Motor and System Order Codes
R
Accumulator Ordering Code
12. ACCUMULATOR, MOTOR AND SYSTEM ORDER CODES

11
12.1 ACCUMULATOR ORDERING CODE

60
Accumulator Model:
A __ __ __ SC __ - __ __ __ - __
Capacity
Gas Precharge
010 - 1.0 ltr.
025 - 2.5 ltr. Pressure in MPa
040 - 4.0 ltr. (10 MPa standard)
055 - 5.5 ltr.
075 - 7.5 ltr.
100 - 10.0 ltr.
120 - 12.0 ltr.
160 - 16.0 ltr.
Fluid Connection
1 - ¾” NPT (standard)
2 - 1” NPT Seal Material
3 - 1 ¼”NPT N - Nitrile (Std.)
4 - ¾” BSPF V - Viton
5 - 1” BSPF
6 - 1 ¼” BSPF
2nd Edition
R
Starter Motor Ordering Code
12.2 STARTER MOTOR ORDERING CODE

61
Starter model: M __ __ - D __ __ __
Displacement
10 - 10cc (0.6 in3)

16 - 16cc (0.95 in3)
22 - 22cc (1.35 in3)
28 - 28cc (1.7 in3)
38 - 38cc (2.32 in3)
66 - 66cc (4.0 in3)
Pinion Gear
Refer to “Fejl! Ukendt argument for parameter.” on

page 12-5 for code
FRG (Flange to ring gear)
Refer to “Fejl! Ukendt

argument for parameter.”
Flange Type on page 12-4 for code
1 - SAE 1
2 - SAE 2
3 - SAE 3
4 - SAE 4
Numerous specials are available
from Powerstart
2nd Edition
R
Pinion Housing Ordering Code
12.3 PINION HOUSING ORDERING CODE

62
Pinion for See assy

Nosecone Flange Spacer Remarks
Housing FRG instr.
M22-H18 (M22-N2) (M22-F1) (M22-S1) 31
M22-H1S (M22-N22) (M22-F1) 51
M22-H37 M22-N2 M22-F3 55 Yes
M22-H3S M22-N1 M22-F3 51 For M22-25-1 and 2
M22-H3S M22-N2 M22-F3 51
M22-H44 M22-N3 M22-F4 25
M22-H46 M22-N3 M22-F4 23 Yes
M22-H48 M22-N3 M22-F4 31.5
M22-HA4 M22-N2 M22-FA M22-S1&6 25
M22-HAS M22-N2 M22-FA 51 Yes
M22-HAS3 M22-N2 M22-FA 51 Yes
M22-HAS4 M22-N2 M22-FA 51 Yes
M22-HBS M22-N3 M22-FB 51
M22-HC1 M22-N2 M22-FC M22-S3 29
M22-HC4 M22-N2 M22-FC M22-S1 25
M22-HD3 M22-N2 M22-FD M22-S2 31
M22-HDS M22-N2 M22-FD 51
M22-HF4 M22-N2 M22-FF M22-S1 25
M22-HF9 M22-N3 M22-FF 45
M22-HG4 M22-N3 M22-FG 25 Yes
M22-HG6 M22-N3 M22-FG 23 Yes
M22-HGA M22-N2 M22-FG 13 Yes
M22-HJ9 M22-N3 M22-FJ 45
M22-HK4 M22-N3 M22-FK 25
M22-HL1 M22-N3 M22-FL 29 Yes
M22-HM1 M22-N3 M22-FM 29 Yes
M22-HNB M22-N2 M22-FN 36
M22-HP9 M22-N3 M22-FP M22-S6 45
M22-HQS M22-N2 M22-FQ 51
M22-HRC M22-N3 M22-FR 19
M22-HS6 M22-N3 M22-FS 21 Toyota forklift
M22-HT6 M22-N3XLD M22-FT 23 Mitsubishi S4S
2nd Edition
R
Nosecone, Flange and Spacer Details
12.4 NOSECONE, FLANGE AND SPACER DETAILS

63
Mounting Nose
Remarks Width Outside dia.
Flange Cone
M22-F1 SAE 1 16 M22-N1 85.6
M22-F3 SAE 3 16 M22-N2 85.6
M22-F4 SAE 4 43 M22-N3 78
M22-F5 SAE 4 35 M22-N4 78.0 Offset 1.7mm
M22-FA SAE 1 Offset 22° CCW 16
M22-FB SAE 3 Offset 3.3mm 16
M22-FC SAE 1 on SAE 3 PCD 23
M22-FD SAE 1 Offset 22° CW 16 Spacer Width Colour
M22-FF M22-FC with dia. 155 Spigot 23 M22-S0 Red oxide
M22-FG F4 Type with dia. 95 spigot on 120 PCD 44 M22-S1 18.5 Orange
M22-FJ FC Type with 144 PCD 23 M22-S2 21 White
M22-FM F4 Type with dia. 89 spigot on 127 PCD 37 M22-S3 14.5 Yellow
M22-FN F4 Type with dia. 105 spigot on 153 PCD 30 M22-S4 13 Grey
M22-FP Special 16 M22-S5 9 Blue
M22-FQ SAE 1 Offset (M22-FB) 3.3mm and 22° 16 M22-S6 6 Green
M22-FR SAE 1 Offset 3.3mm and 13° 16
M22-FS 2 Hole flange 10mm offset dia. 90 spigot 45
M22-FT 2 Hole flange 6mm offset dia. 95 spigot 37
M22-FU SAE 1 Offset 3.3mm 16
M22-FV 2 Hole flange 2mm Offset 49
Flange to Ring Gear Table

Code S 1 4 5 6 7 8 9 A C D
FRG in mm 50.8 29.0 25.5 42.0 23.0 55.0 31.5 45.0 13.0 19.0 16.0
2nd Edition
R
Pinion Gear and Starter drive Ordering Codes
12.5 PINION GEAR AND STARTER DRIVE ORDERING CODES

64
Gear D/P Press Root Over 2

Teeth OD PCD Correction Remarks
Code Mod Angle Dia. Teeth
0 57.1
1 11 6/8 20 57.1 46.6 43.6 20.6 +1 Tooth
2 12 8/10 20 46.4 38.1 35.5 15.6 +1 Tooth
3 10 8/10 20 40.0 31.8 29.2 15.5 +1 Tooth
4 11 3 15 41.1 33.0 28.1 14.3 +2/3 Mod
5 9 3 15 34.5 27.0 21.5 14.1 +0.5 Mod
6 13 8/10 20 46.4 41.3 35.0 14.6 Std.
7 12 6/8 20 57.1 50.8 43.5 19.4 Std.
8 11 8/10 20 44.0 34.9 31.2 15.6 +1.5 Add.
9 9 2.75 15 33.0 24.8 21.3 13.3 +1 Mod.
A 15 10 20 44.4 38.1 33.3 12.1 +0.5 Tooth
B 11 3 15 41.9 33.0 29.1 14.5 +1 Tooth Mitsubishi (Premier)
C 14 10/12 20 41.9 35.6 32.8 12.5 +1 Tooth
D 10 32 15 38.1 30.0 25.1 14.3 +2/3 Mod. MAN (Gali)
E 10 10/12 20 32.2 25.4 20.9 12.4 +1 Tooth
F 20 10/12 20 58.1 50.8 46.8 13.0 +1.5 Add. Volvo 2040 (Matla)
G 9 2.5 15 30.0 22.5 20.0 12.1 +1 Tooth Kubota EB300
H 13 3 20 47.0 39.0 34.0 14.5 1.5 Add. Iveco 8281SR110
J 12 7 20 54.5 43.5 39.2 17.8 +1 Tooth MTU 8V396T833
K 9 8/10 20 36.8 28.6 25.8 15.5 +1 Tooth
L 11 8/10 20 40.0 35.0 28.6 14.5 Std. Lister PH1&2
M 10 12/14 20 26.9 21.2 18.7 10.0 +1 Tooth
N 11 10/12 20 34.7 28.0 25.2 12.7 +1 Tooth
P 11 2.5 15 35.0 27.5 23.8 12.0 +1 Mod. Deutz F3L1011F
R 9 3 20 36.0 27.0 23.6 14.9 +1 Tooth
S 15 4 15 70.6 60.0 52.6 19.2 +2/3 Mod.
Gear Ordering Code Starter Drive Ordering Code
M __ __ - 25 - __ M __ __ - B __
Displacement Gear Code Displacement Gear Code

10 - M10 and M16 From first column 10 - M10 and M16 From first column
22 - M22 and M28 22 - M22 and M28
38A - M38A and M66A 38A - M38A and M66A
2nd Edition
Motor and System Assembly Codes
R
M10 Product Range
12.6 M10 PRODUCT RANGE

65
2nd Edition
R
M10 Product Range
2nd Edition
R
M10 Product Range
2nd Edition
R
M10 Product Range
2nd Edition
R
M10 Product Range
2nd Edition
R
M16 Product Range

66
2nd Edition
R
M22 Product Range

67
2nd Edition
R
M22 Product Range
2nd Edition
R
M22 Product Range
2nd Edition
R
M22 Product Range
2nd Edition
R
M28 Product Range

68
2nd Edition
R
M28 Product Range
2nd Edition
R
M38A/M66A Product Range
12.10 M38A/M66A PRODUCT RANGE

69
2nd Edition
R
Minipak and Pump-Pak Ordering Code
12.11 MINIPAK AND PUMP-PAK ORDERING CODE

70
Pump-Pak model:
MP–P F 1 0
Minipak model:
M P 1 0 __ __ __ F 1 0 1 8
Accumulator
10 - 1.0 ltr (std.)

Starter Size
25 - 2.5 ltr.
10 - 10cc (0.6 in3) 40 - 4.0 ltr.
16 - 16cc (0.95 in3)
22 - 22cc (1.35 in3)
28 - 28cc (1.7 in3)
Hose Length
Starter Drive 1.8m Std.
Pinion gear, flange type

and FRG distance
Refer to pages 12-3 to 12-5
Start Valve
0 - None
F - Foot valve (std.)
C - Cable SSV
M - Manual SSV
P - Pilot SSV
S - Solenoid SSV
2nd Edition
R
Minipak Parts List
12.12 MINIPAK PARTS LIST

71
Item Description Qty Part no. Remarks Weight

1 PumpPak 1 See next page for details 28.5 kg
Depends on
2 Start valve 1 Footvalve (VF) standard Part of pumppak
configuration
3 Starter motor 1 M10 Standard 6.5 kg
4 Pressure hose 1 HS08-18 1.8m long Standard 1.0 kg
5 Return hose 1 HR10-18 1.8m long Standard 1.0 kg
See “ Fejl! Ukendt argument for parameter. ” on page 12-19 for ordering code.
X X X X
2nd Edition
R
Pump-Pak Dimensions and Parts List
12.13 PUMP-PAK DIMENSIONS AND PARTS LIST

72

Depends on
1 Accumulator 1 configuration
2 Mounting bracket base 4 AC-17-1
3 Reservoir 1 RPH-03
4 Hand pump 1 PH-20
6 Internal relief valve 1 PA-006
Depends on
7 Start valve 1 configuration
8 Fittings kit 1 PA-007
See “ Fejl! Ukendt argument for parameter. ” on page 12-19 for ordering code.
X X X X
2nd Edition

Motor de Partida - IPU MANUAL Hy-Starter 12072401

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Table of Contents

2. SELECTION GUIDES ....................................................................................................................2-1

Powerstart Metric Manual

8.5 M22 AND M28 MOTOR PARTS LIST .......................................................................................8-5

11.1 RELIEF VALVE SPECIFICATIONS ......................................................................................11-1

Powerstart Metric Manual

The Powerstart technical team.

Powerstart Metric Manual

Application enquiry form

APPLICATION ENQUIRY FORM

Tel. No.: Model:

Fax. No.: Order no.:

Power (kW): Displacement: (litres):

Break away torque: Running torque (Nm):

Parasitic load (Nm):

Min. cranking speed (rpm): Crank duration (s):

Starter Mounting Arrangement

Flange type (SAE 1 or 2 or 3 or 4):

Flange to ring gear (FRG) in mm:

For any special mounting arrangement please supply drawing.

Pinion Gear Information

Pinion gear no. teeth: Ring gear no. teeth:

Pressure angle 15° or 20°): Diam. Pitch or module:

Outside diameter (mm): P.C.D. (mm):

Rotation (CW or CCW): Is a non-sparking pinion required (Y or N):

Existing Starter Motor

Make/model: Power (kW):

Max. overall diameter (mm): Total length (mm):

System Selection Calculation

SYSTEM SELECTION CALCULATION

Engine breakaway torque

1.3 Torque required Torque at pinion Nm

Torque req'd System press.

Min. engine Gear ratio rpm

Crank duration Starter

2.3 Min. oil vol. Starter revs Starter dis- cc

Minimum oil vol required

Engine Cross Reference Table

2.3 ENGINE CROSS REFERENCE TABLE

Engine Capacity Breakaway Starter

Engine Cross Reference Table

Engine Capacity Breakaway Starter

Engine Cross Reference Table

Engine Capacity Breakaway Starter

Engine Cross Reference Table

Engine Capacity Breakaway Starter

Start Valve and Recharging Systems

2.4 START VALVE AND RECHARGING SYSTEM DIAGRAMS

Hydraulic Piping and Fittings

2.5 HYDRAULIC PIPING AND FITTINGS DIAGRAM

Powerstart Starter Performance Curves

2.6 POWERSTART STARTER PERFORMANCE CURVES

2.6.1 M10 AND M16 STARTER TORQUE CURVES

2.6.2 M22 AND M28 STARTER TORQUE CURVES

Powerstart Starter Performance Curves