SERVICE MANUAL MODEL LS-8 INERTIA DRIVE LUBE-FREE AIR/GAS STARTER POW-R-QUIK EXCELLENCE IN AIR'STARTING SYSTEMS 4540 West 160th St Telephone: 216- and, Ohio 44135-2629 Fax: 216-362.0799 PIN 656.001 Concation ‘gual 1998INDEX SECTION 1 14 Purpose 1.2 Application 2 Parts and Service 1.4 AirlGas Starting System 1.5 Typical Diesel Engine installation, Figure 1 1.8 Typical Gas Engine installation, Figure 1.2 SECTION 2 2.1 Starter. 2.1.8 Starter Designations Table 2-4 SECTION 3 3.4 General 3.50. Inspection 3.2 Periodie Maintenance Inspections, 3.5f. Ait Motor Assembly 4.3 Starter instalation. 3.5.9. Gear Housing Assembt 3.4 Starter Removal 3.5.h, Universal Gear Housing And Flange Assembly, 3.5 Vane Kit instalation, 36, LS-8 Parts Exploded View. See Figure 31 3.52, Disassembly For Vane Kit installation, 3.7, _LS-8 Parts List, 3.5. Inspection, 3.8, 18-8 Vane Kit 3.288 Ps 0 Table 3.1 List. See Table 3.2 35.0 Assembly Of Vane Kit 3.0. 8.8 Rebuild Kit 2.900 Parts List, Seo Table 5.3 3.5.4, Disassembly For Rebull, SECTION 4 4.1 Warranty,SECTION GENERAL INFORMATION 41.4 Purpose, This manual contains installation and service instructions for the POW-R-QUIK model LS- Bineria drive air and gas staring systems 4.2 Application. These systems are primarily utilized in petroleum diiling and production equipment, {935 compressor engines, water well diling rigs, highway vehicles, marine engines, construction ‘equipment, diesel powered generator sets and co-generation equipment. When in doubt regarding the proper staring system for 8 paricular appicaton, we detaled instalation Instructlons should bs reviewed ora POW-R-QUIK starting system specialist should be contacted ‘The LS-8 air starters are designed to operate without any lubrication supplied to the air motor: however, cn applications Involving severe service conditions such as unfiltered air supply, prolonged cranking, or in staring environments with excessive heat bulldups, consult with a POW:-R-QUIK starting system specialist 11.3 Parts and Service. Parts and service are avallale through POW-R-QUIK’s worldwide cistibutor network Lubricstors, operating valves and other STARTING SYSTEM COMPONENTS ARE AVAILABLE INDIVIDUALLY OR 'IN COMPLETELY PACKAGED INSTALLATION AND REBUILD KITS. For guaranteed reliability use only original Pow-R-Quik starting system components. For tha name of the nearest Pow-R-Quik sales and service outlet contact the factory. DESCRIPTION 1.4 AiriGas Starting System, The POW-R-QUIK Model LS-8 inertia drive air and gas starting system consis of vee basle components: The starter, operating valves and air or gas supply NOTE Contact the Pow-R-Quikdistrbutor nearest you for information on genuine Pow-R-Quik stating system components. ‘The LS series can be operated without lubrication for short crank cycles only, Should the cranking time exceed ten (10) seconds, lubrication must be provided to the air motor. itis recommended that lubrication be provided on all starters used with natural gas engines. Operation ofthe LS series without lubrication may cesultin loss of efficiency. 1.8 Typical Diesel Engine installation, See Figure 4.1 1.6 Typical Gas Engine installation, See Figure 1.2 NOTE: CAUTION - PROPER VENTILATION IS REQUIRED FOR ALL ENGINES STARTED BY POW-R-QUIK EXCELLENCE IN AIR STARTING SYSTEMS 4540 West 1 Telephone: 216-362.07% Cleveland, Ohio 44135-2629 Fax: 216-362-0799‘SECTION 2 soidepy (2) Bue 11.90 ate FrdeDy '2-2n4 ‘burs | #ays e seu Li vat uodn a L90H weus Joa ‘r15-8 png ‘s0z5-859 BulOY ang MABUD NEeHY F-STRLON 2 Hey BuO ano 86ubis ¥ #3S © Seu yo1-91 JequIMN By SuzAON Bac, 24 fou) Si1depe Guivnow pus Samu NN Sz OW. Wo TgCHE EST ea wT PEAT FST EON EP) invents zur ‘ngcH 51) Too, zea 28 Asche 8S OEE eS szHes gS) nezHes eS) ‘azeHs 8-59) ‘ngeHs #-S3) ASHES] Ave eS NezH #5 ingen 59] roc 59] etre 33) gre ST Rute ST nese eS ‘nates &51] rein oS) bu BS] Else OHA 8S S058 Ha es 205 Lae wow aug ween Sunway wonei03 Pow ‘pte so ssineoj au) pus ajgeyene saute @-57 0) ou a HiSwBUEISOG URES Pe OaEL age. w pais ‘0¢ ode‘SECTION 3 3.1 General, Experienced mechanics will have no aificuly performing field repairs on the LS.8 starter. For guaranteed quality, use only genuine Pow-R-Quik parts, part kts, and Femanufactured starters All Pow-R-Quik factory remanufactured starters are backed up by Pow-R-Quik's warranty program. 3.2 Perlodie Maintenance Inspections, The following inspections should be performed monthly or during al regular engine servicing or inspections, 1. Ifa lubricator is used, check lubricator for proper operation. If applicable, check the lubricant level and rfl, necessary. 2. fan air fiter with a manval drain fs used, check for moisture accumulation and drain it necessary, Check the fiter olement and clean ar replace as required 3, Inspect ll threaded connections for tightness. 43.3 Starter Installation, 41. Position the starter on the engine flywheel housing wih the starter drive housing propety postioned inthe frwheel housing 2, Align the biot holes in the mounting flange with the proper bows in the flywheel hnousing. Install and properly torque the required bots 3. Install the ar hose on the inlet adaptor. 4. Install exhaust piping or muffler, applicable, 3.4 Startor Removal 1. Remove the air hose from the starters inlet adaptor, if applicable, remove any exhaust Piping or muffler. 2. Leoson, but de not remove the mounting bot, ‘3. Support the starter with one hand and remove the mounting belts withthe ether 4 Remove the starr fom the engine 3.5 Vane Kit installation, 3.60, Disassembly For Vane Kit Installation, NOTE 1. Scribe reference marks en all mating surfaces to assure proper orientation dusing reastembleNOTE Refer to Fig. 3.1 for parts identiication. 2. Remove six screws (#21) and lock washers (#22) from the rotor housing (#1) and separate i from the gear housing (#20), Discard the serews, lock washers and ovings 3. Remove the rotor and casing assembly from the rotor housing (#1) by grasping the ‘dear (#17) and lifting it straight up and out ofthe hosing, 4. Tutn the rotor assembly over and ret itvertcaly on gear (#17) 5. Remove the retaining ring (#8), end plate (#4) and thrust washer #6) ftom the rotor assembly (#5). Discard the retaining ring (8) ana the twust bearing assembly (#9) 18, Remove and discard all vanes (#12 from the rotor assembly (5). 7. Remove the rotor easing (#2) from the rotor astembly by liting it from the inlet end plate (#3) 3.5. inspection, 1. Check all rotor slots for burrs or foreign matter, Clean rotor and remove burrs, 2. Inspect the rotor casing (#2), rotor assembly (#5), end plates (#284) and rotor housing (#1) for damage. Replace damaged parts. Clean all parts that aro going to be used again. 3.5.¢ Assembly Of Vane Kit 41. Place the rotor assembly in a vertical positon resting it on gear (#17) 2. Install the rotor casing (#2) with the long pin (#44) extended through the inlet ‘end plate (#3) 3. NOTE: Be sure that the init air passage batfie on the rotor casing assembly (#2) properly aligns with the sir passage on the inlet end plate (#3) and into the gear housing #20), 4. Insert he five- (5) vanes (#12) nta the rotor slots on the rotor assembiy 5. Install o-rings (#158399) into their respective grooves in bearing rave (#9). 6. Place thrust bearing (# 8) into bore on end plate (#4). Be sure to lubricate bearing propery 7. Install assembled race (#39) into bore of end plate (#4) on top of bearing (#6) with the ings (15 & #39) toward the bearing,8. Place end plate (#4) on to the rotor assembly withthe bearing race against the rotor {and the short pin (#42) extending through the hole in end plate (# 4), 9. Install taining ring (#8) on the rotor assembly (#5) making certain that the snap ring seats properly into the appropriate groove. 10. Install gasket (#40) into the bottom ofthe rotor housing (#1). Use a ight coat of grease tohotd the gasket in place, 14, Fill the cavity in the bottom ofthe rtor housing with grease tothe level of gasket (#40), 12. Place a coating of grease on the rotor shaft to lubricate cup seal (#7) during assembly. 19, Place the now assembled rotor casing into the rotor housing (#2) with the end of the ‘rotor shaft extending through bearing (#11) and cup seal (#7) 14. Postion a new ovsing (#18) on the gear housing (#20), 16, Postion the gear housing (#20) on tothe assembled rotor housing (#1). Work the two together unt the sciived reference marks are aligned and the mating surfaces make contact 16. Install the six- (6) screws (#21) and lock washers (#22) that attach the gear housing (#20) to the rotor housing (#1). Alternately tighten these screws to 6 to 8 lbs. (8.16 40,88NM) of torque. 3.5.4, Disassembly For Rebull 1. Disconnect ail starter air lines, 2, NOTE: Refer to figure 3.1 for parts break down, 3, Match mark all mating surfaces before disassembly begins. 4, Remove six (6) screws (#21) and lock washers (#22) from the rotor housing (#1) and Separate it from the gear housing (#20). Discard the screws, lock washers ang ovings. 5. Remove the rotor and casing assembly from the rotor housing (tl) by grasping the ‘gear (#17) and iting the rotor assembly straight up and oud of the housing (#1) so as ot todo damage to the housina or rotor assembly 6. Turn the rotor assembly aver and rest it vertically gear (#17) 7. Remove the retaining sing (#8). End plate (#4) and theust washer (#8) fom the rotor assembly (#5). Discard the retaining ring (#8) and the thrust bearing assembly (#9, 39, 15.86), 8, Remove and discard all vanes (#12) rom the rotor assembly (#5).8. Remove the rotor casing (#2) ftom the rotor assembly by liting it fom the inlet end Plate (#3). 40. Remove ans discard retaining ring (#8) fom the gear end of the shat. 11, Lit gear (#17) from the shaft 12. Remove woodruff key (#13). 18, Remove ard plate assembly (#3) from the retor shaft (#5) by supporting inlet end plate (#8) and pressing onthe rotor shaft (#5), 14, Remove bearing (#16) from inlot (#9) with the use of a bearing puller 18, Remove and discard oxings (#8 14 &15) from inlet end plate (#2). 16. Remove and discard at this ime thrust beating assembly Ws 6, 15,39 & 9) 17. Remove and discard bearing (#11) from rotor housing (1) with the use of a bearing puller 18. Remove and discard cup seal (#7) from rotor housing 419. Remove and discard gasket (#40), 20. Remove and discard screws (#96) and lock washers (#22) from gear housing (#20) ‘and remove drive Rousing (#34), 21, Remove and discard o-ring (#32). 22. Grasp drive (#33) and pull to remove the érive, arbor shaft and gear assembly from the ‘gear housing (#20) 23. Remove and discard retainer (#25). 24. Support sealing spacer (#91) and with a suitable mandrel press on the gear end of ‘arbor shatt (#28) to remove i #28) trom the sealing spacer (#3) and gear (#26), 25, Remove and dseard oxings (#27, 20 832) 20, Remove woul ey (818) fom wor sha (29), 27. Compress drive (#33) and remove crive pin (42) 28. Remove dive (#3) from arbor shaft (#28. 28, Remove and discard bearing (#24) fom gear housing (20). 3.5e. Inspection 1. Inspect the starter drive for visible damage or slippage. Replace if necessary2. NOTE: A replacement starter dive is not included in the LS-8 rebuild kit 3. INSPECT ALL PARTS. Clean all usable parts (except the starter drive) in a good ‘commercial grade clearing solvent, and dry with compressed air. Replace any parts ‘that can not be reused, 4. CAUTION: Do not apply solvent to the starter drive, as it may remove the factory- ‘pplied lubricant 5, Check ll rotor slots for burs or foreign mater. Clean rotor and remove burrs 6. Closely inspect the rotor casing (#2), rotor assembly (#5), end plates (#384) and rotor housing (#1) Replace any parts tet can not be reused, 3.54. Alt Motor Assembly, 41 Install cup seal (#7) nto rotor housing (1) withthe seals lp toward the inside ofthe case, 2. Press bearing (#11) into the rotor housing (#1) 3. Lubricate thrust bearing (#6) and place it into the shallow bore of inlet and plate (#3), 4. Install o-rings (#16839) in heir appropriate groaves on thrust beating race (#8), 5. Install race assembly (6) into the shallow bore on top of bearing (#6) with the o-rings (#15838) toward the bearing, 6 Install O-rings (#14815) into thee proper grooves in inlet end plate (3). 7. Place assembled inlet end plate over the keyway end ofthe rotor shaft assembly (#5). 8. Support rotor assembly (#5) n a press with the key way up, 9. Install woodrut key (#12) into keyway on rotor shaft (#5). 10. Position bearing (#1) into its bore on inlet end plate (9). 11. Align gear (#17) with key (#13) on shatt (5) and press until bearing (#16) is seated in inlet end plate (#3) and retainer ring (#18) can be installed into Is) groove on rotor shaft (#5). Make sure that the rotor tums freely 12. Place the rotor assembly in a vertical position resting it on gear (#17)19, NOTE: if roll pins (#4183#42) have been removed during cleaning and inspection, reinstall them now. When assembling a right hand rotation starter. place the rotor casing (#2) ina vertical positon with the air inlet opening at six o'clock and the roll pn hole at the one o'clock postion. Install the long roll pin (#41) in the one o'clock positon, now tum the casing over and instal ol pin (#42) in the remaining hole. Ifthe Starter motor is lefthand rotation model, position the rolor casing vertically with the air inlet at six o'clock and the rol pinhole at eleven o'clock. Install the long pin in the ‘leven o'clock hol, tum the casing over and instal the short pin to make a fet hand rotating starter. 14, Let end plate (#3) and retainer ing (#18) can be installed into its’ qroave on rotor shaft (5). Make sure thatthe rotor turns freely. 16, Insert the fve- (6) venes (#12) Into the rotor slots in the rotor assembly (#5). The beveled side ofthe vanes should be toward the rotor shaft. Be certain the vanes move freely in the slots. If there is any binding or sticking at all find the reason and alleviate itat this time, 16. Install tings (#5 15 & 39) into ther respective grooves in bearing race (#9). 17. Place thrust bearing (#6) into end plate (4), 18, Install thrust bearing (#6) into end piate (#2). 19, Install thrust Bearing race (#9) into end plate (#4) on top of thrust bearing (#6) with the ofings toward the thrust bearing. 20. Place end plate (#4) over rolor shaft (#5) withthe trust bearing and race tothe inside ofthe assembly making certain the short rol pin (#42) extends through the hole in end plate (#4). 21. Install retaining ring (#6) on the rotor shaft (#5) making certain the ring is set into the appropriate groove na satisfactory manor 22. Install gasket (#40) ino the bottom of rotor housing (1). Use a light coat of grease to hold the gasket in place, 29. Fill the cavity in the bottom of the rotor housing with grease to the level of the gasket (#40) surface, 24, Place the now assembled rotor and casing assembly info the rotor housing (#1) with the end of the rotor shat extending trough bearing (11) and cop seal #9), NOTE Position the rotor and casing assembly in the proper orientation at this time. Pin (# 41), ‘must be in the correct postion in order fort to align withthe indexing hole in the gearbox (20)3.5.9, Gear Housing Assembly, 1. Press beating (#24) nto gear housing (#20) 2. Install plug (#28) no the appropriate hole in gearbox (#20), 3. Postion a new aig (#18) on gear housing (20), 4. Position the gear housing (#20) on to the assembled rar hnusing (#1). Work the two together until the mating sudfaces make contact. 5. Install the six(6) serows (#21) and the lock washers (#22) that attach the gear housing (#20) tothe rotor housing (#1). Alternately tighten these screws to 6 to 8 ft Ibs. (8.16- O.86NM). 6. Install Oving (#27) on arbor shaft (#20), 7. Install Woodruft key (#13) on arbor shaft (#29) 8. Install drive (#33) on arbor shaft (#23). Compress cive in such a way so thatthe drive bin (#28) can be installed through the aligned holes in the atbor shaft (#28) and the rive (33), 8. Place sealing spacer (#31) over arbor shatt (#29) with the large diameter toward the Pinion, 40. Install o'ing (#30) in the groove formed between the sealing spacer (#84) and the bottom ofthe crive (#33) 111, Place gear (#26) on to arbor shaft (#29) and install retainer ring (#25), 42, Install drive, shaft and gear assembly into tre gear housing (#20). 18. Install ing (#82) into the groove formed between the gear case (#20) and the sealing spacer (#31) 14, Press bearing (#97) into the bore of érive housing (#34 or 35), 15. Install drive housing (#34 or #35) In the proper orientation onto gear housing (#20) secure with serew (#86) and lock washer (#22). Torque to 6 ta 8 bs. 3.5. Universal Drive Housing And Flange Assembly, 41, When universal drive housing (# 35) is used a mounting flange (#36) and often the shims (#46) must be used as well 2, Place the appropriate amount of shims (#48) over the nose of the universal drive housing (#35). Place the universal-mountng lange (#38) ovar the nose of the universal ‘ive housing (#35). Put the flange inthe proper arientation to the drive housing. align ‘ne sie holes and bolt the assembly together with socket head cap screws (#43) nuts (#45) and lock washers (#44), Torque to 6108 ft Ibs.3, Bench test the rebuit starter, using @ three quarters of an inch ait hosé and / or install ‘on the engine for testing, A. Insta the air nes, ‘5. Engine test the state. 3.6. LS-8 Parts Exploded View. See Figure 3.4 37. 18.8 Parts List Seo Table 3:4 3.8, .$-8 Vane Kit 3-288 Parts List, See Table 3.2 3.9, LS-8 Rebuild Kit 3.868 Parts List See Table 3.3Figure 3.1 LS.8 SERIES STARTER EXPLODED PARTS VIEWTable 34 LS-8 SERIES STARTER PARTS LIST INDEXNO.| PARTNO. [DESCRIPTION ay __| Per uur z e106 [Rotortoaing o z 78-104R [Rotor Casing PUGH Handy i 7ee(04t [Rotor Cesng (et Hand) | z 8-503 End Pate (Rg Fe). 8-503 — nt end Plate (et Hac) a "-502R— [End Pate Right Hand) 48-5021 End Plate (Let Hard) 18-101 [Rotor Asromby 7s — [Tt Gearing e124 Rota Rg W716 [Race 103 mar Oar 7-102 — [Boring 125105 [Rotor vane — 17-316 —|Wooart Kay 25427 —[ORing 7-201 —JORng 7-105 [Bearing 19-120 |Gear= a0 Rata 15-144 |Gear= 144 Ratio @) 18175 [oear= 1.75 Ratio (Standard c-120—[Reaing Ring z "7-209 Oring = i “e-508_ [Gear fausing i =110—|Serew = é 7-112 —]Locwashor iz 32500 [Pg i rio; —|eearng - 4 ietainng Re i [Gear 1.20 Rata i [Sear—1.44 Ratio ©) - [Gear 1.75 Ratio (Standard) [Oring i rive Pia - t [arbor shail (471 aa. Pinion) 1 {Arbor Shaft (625 dia. Pinion) fori. - i [Sealing Spacer 4 [Owing 1 Drive Pinion (See Table 27 a [Drive Housing (See Table 2.7) i [Universal Drive Hovsing| 7 Screw i 7 i z Bushing ees [Universal Rouning Flange (See Table 2) forRing ieasket Cong Rollin [Short Ral Pin cs (Cap Screw. Lockwasher ut (adaptor Shim "MUST PROVIDE MODEL NUMBER OF STARTERTable32___VANE KIT 3.288 FOR LS-8 SERIES STARTER PARTS LIST ‘QUANTA noeX wo. | PaRTNO. oescriPn " ren PER UNIT & 7-16 [Tani Be = aT-i24 Retaining Ri @ T7116 [Race 7 12-105 [Rotor Vane 15 47-201 OR: 1S 1-200 [OR zi eit [screw 22 "-112— [Lockwasher Table33___ REBUILD KIT 3-888 FOR LS-8 SERIES STARTER PARTS LIST INDEXNO.| PARTNO, [DESCRIPTION ean PER UNIT a airs Thre Boars ria [seal “Triad [Retaing Ri rite [Race “T-i02 [Bear 2-105 [Rotor vane. T7316 —_[WoodrutKo e127 —TORng a-201_JOR 7-103 Bea 17-120 [Retain 17-209 [OR Trio — [screw “Trig —_[tockwasher “T7101 [Beat “ra JRetaining 7-208 —[oRin 7-203. [ORin 17-207 [orn 7-17 —Iserew 78-100 Bush Sei61 JOR 5-105 [Gasket SECTION 4 41.Warranty PowsR-Qhik provides a limited warranty on the products it manufactures {and sells under the company name against the fallure to perform properly within certain lets of ime, application, performance, installation, abuse and alteration because of a defect in material andior workmanship, Copies of Pow-R-Quik’s standard product ‘warranties are provided with is products and its dstibutordealer sales manuals and are available upon request from Pow-R-Quik Pow-R-Quik standard product warranties will aply and Distributors, Dealers, Sales Representatives, or Agents are not authorized to make other warranties on resale with ‘aspect to Pow-R-Quik. Itis imperative thatthe product warranty be read carefully. Pow. R-Quikis not obligated to incorporate new design modifications to products in service «xin the Oistrbutor or Dealer inventories.