W200

21
Starting air system

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 W200

Starting air system ................................................................................................................................3

21.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

21.2 Starting devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

21.2.1 Description (see fig. 21-01 a and b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

21.3 Air starting motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

21.3.1 Air starting motor for V12 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
21.3.2 Air starting motors for V16 and V18 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
21.3.3 Air starting motor for all types of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

21.4 Air starting motor lubrication (only on V18 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

21.4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21.4.1.1 Servolubricator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
21.4.1.2 Oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
21.4.1.3 Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
21.4.1.4 Flow rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
21.4.1.5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

21.5 Implementation and maintenance of the pressure regulating valve (only for V18 engines) . . . . . . . 11
21.5.1 Operation and characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21.5.1.1 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
21.5.1.2 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

21.5.2 Installation on piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

21.5.3 Different methods of charging the reservoir (see fig. 21-10). . . . . . . . . . . . . . . . . . . . 13
21.5.4 Special precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
21.5.5 Prolonged storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21.5.6 Verification and testing after maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . 14

21.6 Compressed air container and pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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 W200 & W220 Starting air system 21.

21. Starting air system

21.1 Description
The engine is fitted with a starting motor with a previous engaged
pneumatic control turbine designed to operate with compressed air.
Small quantities of solid or liquid foreign matter in the compressed
air should not normally have a detrimental effect on the starting
motor. Also, it is not at all necessary to lubricate the compressed air.
Four main zones are differentiated in the starting motor :
• Input casing - diffuser / valve seat
• Turbine body
• First gear support stage
• Gearbox.
When the engine speed reaches 150 rpm, the current is cut by relay
(item 3) of the electronic tachometer, which automatically de-
clutches the starting motor.
In case of power failure or malfunctioning of the governing devices
(item 1), (item 2), (item 3) or (item 4), the engine may be started
with manual valve (item 5) in case of an emergency. Remember that
automatic declutching of the starting motor is then out of service
and consequently, when the engine starts, it is necessary to close
valve (item 5) to prevent the starting motor from overspeeding.
Valve (item 6) stops starting when the cranking gear is engaged, and
also impeded emergency starting with valve (item 5).

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 21. Starting air system W200 & W220

Starting air system diagram - W200 engines

1. Air container
2. Pressure regulator
3. Gauge for starting air
4. Safety valve
5. Main starting valve
6. Starter control valve
7. Starting motor
8. Start blocking valve
9. Pneumatic stop cylinders
10. Main stop valve P

STARTING AIR

Fig 21-01 a

Starting air system diagram - W220 engines

2. Pressure regulator
3. Gauge for starting air
4. Safety valve
5. Main starting valve
6. Starter control valve
7. Starting motor
8. Start blocking valve

Fig. 21-01 b

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 W200 & W220 Starting air system 21.

21.2 Starting devices

21.2.1 Description (see fig. 21-01 a and b)
The engine is fitted with a starting motor designed to operate with
compressed air.
When the engine speed reaches 1500 rpm, the current is cut by relay
of the electronic tachometer, which automatically declutches the
starting motor.
Valve (item 8) stops starting when the cranking gear is engaged, and
also impedes emergency starting with valve (item 5).

21.3 Air starting motor

21.3.1 Air starting motor for V12 engines
This modele is a turbine driven air starter with a pre-engaged starter
drive. It is suited for W200 and W220 engines. It comes complete
with a pilot air solenoid valve installed.
An electronic control module reads output shaft speed and shuts off
air to the inlet in a unloaded or an overspeed condition*.

Fig. 21-02

* only for W200 engines

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 21. Starting air system W200 & W220

21.3.2 Air starting motors for V16 and V18 engines

These starters are equipped with a pneumatic motor with rotor
geared whose shafts are installed on needle bearings.
The distribution valves are built-in on the starter to form a compact
unit.
This type of starter requires permanent lubrication.

Fig. 21-03

21.3.3 Air starting motor for all types of engines

This new generation, equipped with tight bearings do not require lu-
brication and maintenance.

Fig. 21-04

The centre of gravity is close to the flange to give stiff starting.

Nota : This model is suitable for all W200 and W220 engines.

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 W200 & W220 Starting air system 21.

21.4 Air starting motor lubrication (only on V18 engines)

21.4.1 Description

Fig. 21-05

21.4.1.1 Servolubricator operation

Principle and connection :

Fig. 21-06

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 21. Starting air system W200 & W220

When the starting motor begins to operate, the air is fed by the pipe
(item A) in the chamber (item B) and actuates the piston (item C).
The oil in the chamber (item D) closes the valve (item E), passes by
the closing valve (item F) and the pipe (item G) and is injected in
the starting motor supply pipe via the valve (item H).
At the end of the starting operation, the pipe (item A) is vented by
the control system and the pressure drops in the chamber (item B).
The spring (item I) then pushes the piston (item C) while the closing
valve (item F) sucks oil from the tank by valve (item E). The
chamber (item D) is filled with oil which will be injected during the
next starting operation.

21.4.1.2 Oil filling

Filter (item J) must be fitted when filling the tank to eliminate any
possible impurities in the oil.
• Capacity : 200 cm3.
For the characteristics of the lube oil, see chap. 02.

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 W200 & W220 Starting air system 21.

21.4.1.3 Priming

1 23

Fig. 21-07

Connect the servolubricator as per fig. 21-06.

Adjust flow rate to maximum (item K).
Operate the control (see fig. 21-07 & 21-08) several times until oil
flows from the pipe (item G). Then connect as per 21-06 and adjust
to the required flow rate (see chap. 21.4.1.4).

Fig. 21-08

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 21. Starting air system W200 & W220

21.4.1.4 Flow rate adjustment

The servolubricator is used to inject, at each cycle, a quantity of oil
varying from 0 to 6 cm3.
The flow rate is adjusted using a screw (item K) modifying the ca-
pacity of the chamber (item D) by adjusting the stroke of the piston
(item C).
Fully tighten the screw (item K) to obtain maximum flow. Gradually
unscrew to decrease this flow rate.
The recommended adjustment for a starting motor operating under
normal conditions is approximately 3.5 to 4 cm3 per start-up. The
quantity of oil injected can be seen on the vernier located on the ser-
volubricator body, opposite the adjustment screw (see fig.21-09).

Fig. 21-09

21.4.1.5 Maintenance
No special maintenance is required on the servolubricator.
However, occasionally check that it operates correctly (movement
of the piston in the vernier) (see figure 21-06).

Warning : Make sure that the oil level is always above the minimum. Top
up the oil every 80 start-ups approximately.

Note : A proper lubrication eliminates the detrimental effects due to

condensation.
For the recommended lube oil, see Chap. 02.

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 W200 & W220 Starting air system 21.

21.5 Implementation and maintenance of the pressure

regulating valve (only for V18 engines)
21.5.1 Operation and characteristics
21.5.1.1 Operating principle
The dome cap reservoir must be charged with neutral gas or air at a
pressure corresponding to what is required downline. To increase
the pressure downline, simply increase the pressure in the reservoir.
To decrease the pressure, reduce the pressure in the reservoir (the
latter mentioned operation must be carried out during operation or
after having previously bled the circuit downline from the pressure
regulating valve).

21.5.1.2 Characteristics
• Standard die cast brass construction.
• Balanced valve (fully tight when closed).
• Tapped connection ports (BSP).
• Reservoir control port, tapped, ¼ “ BSP.
• Permissible upline pressure 100 bar.
• Downline pressure 0.5 to 40 bar.

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 21. Starting air system W200 & W220

21.5.2 Installation on piping

The unit must be connected to the piping in compliance with the
fluid flow direction indicated by an arrow on the body of the unit.
The input and output ports are tapped (BSP).

26
12

13
22 bar 16B
16A
18

2
17
Outlet 22 bar inlet 100 bar
5
7
6

Fig. 21-10

Item Description Quantity

2 O-ring 1

5 O-ring 1

6 Spring 1

7 O-ring 1

12 Membrane 1

13 O-ring 3

16A Discharge needle 1

16B Discharge needle 1

17 Teflon bush 3

18 Teflon bush 2

26 Pressure gauge connector 1

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 W200 & W220 Starting air system 21.

21.5.3 Different methods of charging the reservoir

(see fig. 21-10)
a) Using upline pressure (40 bar maxi) and downline pressure (22
bar) :
• Slightly open the upline and downline valves so that the
pressure regulating valve is in flow position (downline,
disconnect the electrovalve and press the pushbutton).
• Slightly open the discharge needle (item 16B) using a hex
head key until the required expanded pressure is read out
on the downline pressure gauge. Close the needle.
If the downline pressure is greater than the required pressure, open
the discharge needle. When the required pressure is reached, close
the needle.
The unit is ready to operate.
b) Using an external pressure source which must be connected to
the 1/4" BSP port of the reservoir.

Remark : The pressure indicated by the reservoir pressure gauge is very

close to the actual output pressure (plus or minus 1 bar).

21.5.4 Special precautions

• Excessive torquing to charge and discharge needles du-
ring closing can be detrimental. The maximum torque to
apply is 2,5 Nm.
• Depressurise the reservoir when there is no upline or
downline pressure from the pressure regulating valve
(inspection or maintenance operation).
• Before replacement if required, check the type of O-rings,
the membrane and the valve seat indicated on the techni-
cal data sheet appended to the unit.

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 21. Starting air system W200 & W220

21.5.5 Prolonged storage

a) Before storage : depressurize the reservoir and the air circuit.
b) Return to service : If the storage is greater than 6 months, disas-
semble the unit, replace the seals and slightly lubricate with appro-
priate grease (Oxigenoex for Oxygen).

21.5.6 Verification and testing after maintenance

work
1 Do not forget to slightly lubricate the seals and especially
the moving seals.
2 Check valve tightening.
3 Check for external leaks with “snoop”.

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 W200 & W220 Starting air system 21.

21.6 Compressed air container and pipes

The starting system is designed to prevent explosions.
An oil and water separator and a check valve must be installed on
the supply pipe between the compressor and the compressed air
container. A bleed valve must be installed at the low point of the cir-
cuit. A check valve and a safety valve are immediately installed
upline from the circuit.
Bleed condensation from the container before starting.
Prior to installation, carefully clean the piping between the com-
pressed air container and the engine. During use, protect it from
dirt, oil and condensation.
Inspect the compressed air container and clean it on a regular basis,
then coat it with an anti-corrosion product and allow to dry for a
sufficient amount of time. At the same time, inspect valves: exces-
sive tightening may damage the valve seats, causing leaks. Leaking
worn valves, including the safety valve, must be ground. Test the sa-
fety valve under pressure.

Caution : According to the local regulations, the compressed air con-

tainer(s) may be inspected periodically by an approved orga-
nism.

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