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Accumulator

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SERVICE INSTRUCTIONS

Handraulic

StartersCONTENTS

Information Spare Parts

Introduction 1 ----

Approved hydraulic fluids and greases 1 ----

Safety precautions 2 ----

Working principles & operating instructions 3 ----

Servicing 5 ----

Starter Unit 5 17

Hand Pump & Pressure Gauge 8 19

Relay Valve 10 20

Accumulator 10 21

Filling and Venting the System 10 ----

Pipe Connections 11 22

Routine Maintenance 12 ----

Trouble Shooting 13 ---- 1

INTRODUCTION

This handbook is provided to help the operator to obtain the best service from the

Prestolite Handraulic Starter. Normally the starter is “trouble free”, but damage or

unusual conditions of service may necessitate examination of the system for faults.

After long service it may be necessary to replace worn parts.

The letter G in the starter unit typecode i.e. B50G53 identifies the direction of rotation,

and indicates suitability for engines having clockwise rotation of the crankshaft viewed

from the free end.

Please quote the unit typecode and component part number when ordering spare parts.

Only use genuine Prestolite Parts and approved Hydraulic Fluids and greases in the

starter installation. The use of spurious parts or incorrect fluids may cause failures, and

will invalidate claims arising from their use.

Approved Hydraulic Fluids and Lubricating Greases:

For operation in temperatures below –10° only fluids conforming to specification OM15

are suitable, and the following brands are approved: Prestolite only supply fluid

conforming to specification OM15.

Castrolareo 585B Esso Univas FJ13

BP Aero Hydraulic 1B Mobil Aero HFE

Shell Areoshell 41

Lubricating Grease Shell Alvania RA.R2

For operation in temperatures above –10° fluids conforming to specification OM13 and

OM15 are suitable. The following brands conforming to specification OM13 are

approved:

Castrol Hyspin AWS15 Mobil DTE21

BP Energol HLP15 Shell Tellus T15

Esso Nuto H15

Lubricating grease, Shell Alvania RA, R2

Castrol Spheerol MP2, L-EP2 2

SAFETY

Detailed notes are included in the operating and service instructions where appropriate,

and are summarised below.

SAFETY PRECAUTIONS

1. Do not disconnect pipe joints with the system under pressure. Discharge the

accumulator first by operating the relay valve.

2. Do not operate the starter unless the starter unit is secured to its mounting

bracket on the engine. During starting the starter pinion is fed forward and

rotated at high speed, and the engagement teeth can inflict serve injury.

3. Do not remove spring retaining nuts, circlips or other retainers without first

ensuring that the spring is prevented from releasing suddenly.

4. Do not attempt to dismantle nor flame cut the accumulator. It is permanently

charged with nitrogen gas at high pressure.

5. If the accumulator is to be scrapped, follow the guidelines as described on page

19.

6. Do not use lubricating oil or vegetable based oil (such as automobile brake

fluid). Use only the hydraulic fluids recommended on page 1. 3

WORKING PRINCIPLES AND OPERATING INSTRUCTIONS

The Prestolite Handraulic Starter system is shown in Figure 1, and uses a combination

of pneumatic and hydraulic principles to store and release energy for engine starting.

The essential units are: -

Feed Tank / Hand Pump Hydraulic Accumulator

Pressure Gauge Relay Valve

Starter Unit Engine Dog

Connected by high-pressure tubing.

The Starter Unit is attached to the free end of the engine by a mounting bracket, and the

engine dog is attached to the crankshaft using a suitable adapter.

The heart of the starter is the Hydraulic Accumulator, which comprises a cylinder

closed at each end, in which a leak-proof piston is free to slide. Above the piston the

cylinder is pre-charged with nitrogen to a pressure of approximately 200 bar

(2900lbf/in2

) and permanently sealed. Under these conditions the piston rests at the base

of the cylinder.

By operating the Hand Pump, hydraulic fluid is drawn from the feed tank and pumped

into the Accumulator below the piston until the piston has been displaced sufficiently to

raise the nitrogen and fluid pressure to approximately 310 bar (4500 lbf/in2

The Starter Unit incorporates two opposed cylinders, each containing a rack in mesh

with a common pinion. This pinion has face teeth at one end; during starting this drives

a dog having corresponding teeth, which is attached to the engine crankshaft.

Two helical grooves formed in the periphery of the pinion are engaged by spring loaded

balls incorporated in the starter housing; these impart a forward axial movement to the

pinion to effect its engagement with the engine dog, positive engagement being

maintained by the helical tooth-form of the pinion and racks.

Operation of the Relay Valve lever admits hydraulic fluid at high pressure to the Starter

Unit racks, bringing the pinion into engagement with the engine dog and imparting a

high rotational speed to the engine crankshaft.

OPERATING INSTRUCTIONS

First ensure that the engine is in a ready-to-start condition, primed with fuel and at full

compression. If the engine has not been started since leaving the manufacturers works

check the Starter and Engine for freedom as described on page 13.

Check that the Feed Tank is filled to the correct level with approved hydraulic fluid and

vented as described on page 10 “Filling and Venting the System”. Raise pressure to

between 276 and 345 bar (4000-5000 lbf/in2

) using the Hand Pump.

To fire the engine pull the Relay Valve operating lever until resistance is felt

(about 45°), then continue until the lever has reached its stop. The Relay Valve

lever operates a two-stage valve, and should not be snatched or jerked.

The first stage allows a slow bleed of pressurised fluid to the starter racks, causing slow

rotation of the starter pinion accompanied by its forward axial movement until it is

engaged with the engine dog. 4

The second stage releases the full flow of fluid at high pressure to the racks; this

provides the starting impulse.

When the engine starts, the lever is released to return to its normal position. Springs

return the racks to their original position and the pinion retracts. Fluid from the starter

unit is returned to the feed tank, via ports in the Relay Valve, ready for the next

charging of the accumulator.

The engine can be inched over for making adjustments or checking freedom, with the

accumulator discharged, by holding the Relay Valve open and operating the Hand

Pump.

A single Accumulator contains sufficient oil for one starting impulse when used with

the B50 Starter Unit, and three impulses with the smaller B35 Starter Unit, before oil

recharging by operating the Hand Pump. 5

SERVICING THE HANDRAULIC STARTER

The numerical references used in the text to identify components correspond to item

numbers used in the Spare Parts Lists.

Before dismantling any equipment, or carrying out any servicing, it is essential for the

workbench, tools and component trays to be scrupulously clean.

Only clean diesel oil should be used for washing purposes. We do not recommend using

paraffin (kerosene) as it can contain water, which may cause corrosion.

Particles of dirt or any foreign matter in the starter system will lead to premature failure,

by causing valves to leak, damaging seals, or obstructing small orifices in the Relay

Valve.

Seals and washers should be renewed if there is any doubt of their suitability for further

service, and copper washers annealed before use.

STARTER UNITS B35G8 AND B50G53

The following instructions apply to both of the above units except where stated. Refer to

page 17 for illustration.

Detail difference between B35G8 and B50G53

On B35G8, rack travel is arrested by a mitred shoulder abutting a circlip fitted to a

groove machined in the cylinder.

On B50G53, rack travel is arrested by a flat shoulder abutting a stop washer (20)

clamped between cylinder and housing.

Do not operate the starter unit unless it is secured to the mounting on the engine.

During operation the starter pinion is fed forward and rotated at high speed and

engagement teeth can inflict severe injury. To assist dismantling and assembly a firmly

fixed mounting plate, and peg spanners as shown in fig 2 are necessary in addition to

normal workshop tools.

Dismantling

Bolt the starter housing to the mounting plate.

Unscrew the front cover (2). Remove the pipe assembly after unscrewing pipe nuts at

each end of the starter unit.

Remove the stud coupling (30) and washer (29).

Slacken nuts (12) retaining the end covers

IMPORTANT

Note that these nuts are the sole means of retaining the end covers and holding captive

the rack return springs. Each end cover should be held firmly while the nuts are being

removed, and the springs allowed to expand slowly against hand pressure until they

exert no further force. Note from which side of the centre housing each cover is

removed as the dowel and spring plug (7,8) have alternative positions on assembly.6

To withdraw the pinion.

If the purpose of dismantling is solely to change the pinion, refer now to re-assembly

page 7.

Using a peg spanner Figure 2, remove each cylinder cover (10). It may be necessary to

clamp each cylinder to prevent rotation, using a strap wrench or pipe clamp

(46mm/1.81” – B35, 64mm/2.52” – B50).

Push out the rack assemblies. Unscrew each cylinder, and remove the stop washers (20).

Keep these with their respective racks and cylinders, and note from which position on

the centre housing each was removed.

Wash all parts in clean fluid, dry – preferably by air blast, and inspect for damage, wear

and corrosion. Remove any burr from the helical grooves of the pinion using an oil

stone.

Assembly

Racks and Cylinders

Inspect the “U” seal and backing ring (17,18) and joint ring (11) and fit replacements if

necessary.

The sealing lips of the “U” seal, and its back face must be free from cuts, tears or other

discontinuity. Radial marks on the back face indicate the leakage has been occurring

past the inner sealing lip.

The PTFE backing ring should be replaced if the thickness is below 1mm for B35 or

2mm for B50.

A small fringe, which may form on the back face, should be cut off carefully flush with

face using a sharp knife or razor blade.

When fitting new seals, they and the rack should be greased lightly to prevent the seals

being twisted or damaged. See figure 3 for correct assembly. Note that the chamfer in

the bore of the backing ring must face away from the “U” seal. 7

Refit rack stop washers in their original position unless they are damaged or faulty, in

which case use new washers of the same thickness.

Renew cylinders if bores are scored, rough or rusty.

Screw and tighten the cylinders into the centre housing, ensuring that each is fully home

and clamping the stop washer against the housing. Smear the rack assemblies and

cylinder bores with grease. Slide the rack into the cylinder taking care not to damage the

backing ring or sealing lip of the “U” seal as they enter the honed bore and push each

fully home.

Put the pinion in position, and push the racks inwards simultaneously. With pressure

maintained, check that the pinion is free to slide, and that there is a small amount of

backlash between pinion and rack teeth.

If the Pinion is not free, reverse the position of the racks.

Retract adjusting screw (14) so that the underside of the head is flush with the cover

face (10) but without distorting spring (15).

Using a new joint ring (11) replace the cylinder cover (10) and tighten firmly.

Remove the pinion, and push the racks outwards to the full extent of travel.

Grease the pinion, slide it into mesh with the racks, and push it fully into the housing.

Check that each of the helical grooves cut in the periphery is visible in the larger of the

two holes (for the spring cups) on each side of the centre housing.

Put the steel balls in the spring cups, springs, spring guides and rack return springs

(2 each side on B35, 3 on B50).

Re-fit the end covers, making sure that each is assembled to the correct side of the

centre housing. The two holes each side for the locating dowel and spring cup are

reversed in position, and the spring plug and dowel assembly position in the end cover

is varied to suit.

Check and adjust if necessary the axial position of the pinion, to a dimension of

2.5mm +/-0.2mm from the starter mounting flange to the tops of the teeth.

The adjustment is by rack adjusting screws fitted in the cylinder cover.

Adjust the screws by equal amounts, ensure that the pinion is still free. Clockwise

rotation of the screws causes the pinion to advance.

Refit the stud couplings, and pipe assembly.

HAND PUMP 6518-35 Refer to page 18.

SERVICING

Three spare part kits are available for the pump as shown on page 19.

1. Seal Kit 6518-39

2. Gauge Kit 6518-28

3. Linkage kit 6518-29

DISMANTLING TO REPLACE SEALS

Note: Make sure the tank is fully drained and then grip the pump tank securely in a vice

before trying to dismantle. Remove the gauge and linkage assembly first to reduce the

possibility of damage to these items. It is recommended that only seal replacement be

carried out on the pump. Other pump faults are serviced by replacement.

Gauge Assembly

Remove the gauge assembly using a 19mm spanner. The gauge requires little

maintenance except checking for any leaks, and if the gauge is faulty it is serviced by

replacement with service kit 6518-28.

Linkage

Remove the circlips and withdraw the 2 pins and levers from the lever support housing.

Pay particular attention to wear of the pins (1) levers (25) and lever support (7). Replace

any parts, which are worn, damaged or otherwise unsuitable for re-use with service kit

6518-29.

Main Pumping Piston

Remove the main piston by inserting a suitable bar in the hole on the end of the piston

then slowly turning and pulling the piston assembly, withdraw the main piston from the

piston housing body. Using a 50mm A/F spanner remove the piston housing and then

remove o’rings (53, 54). To replace the top and bottom seals (33, 34) remove them

using a pointed scriber to prise them from their recesses noting which way round they

go and replace.

Filter

Undo the filter plug located at the back, on the right hand side of the pump. Then using

pointed pliers pull out the filter mesh (2) from its seating. Clean the filter mesh.

Relief valve

The relief valve is on the right-hand side of the pump. Remove the main body (38),

washer (4) and steel ball (37). Do not undo the locknut (39) and alter the adjusting

screw setting (40). If the relief valve is leaking past the adjusting screw (40) it will be

necessary to replace seal (35). Remove the spring assembly (36, 41, 42) from the body

to remove the seal (35) for replacement. 9

Tank O’Rings

Undo the tie bar nut (50) using a 17mm socket and washer (48) to remove tank from the

pump body. Push out the top plate (45) and remove the o’rings (46). Replace o’rings as

required.

CLEANING

Clean pump body and internal parts after dismantling using a fluid for use with viton

seals i.e. clean diesel oil. Blow out all galleries and ports before re-assembly.

Replacement of any damaged or worn seals is by Hand pump service kit 6518-39.

ASSEMBLY

Assembly is a reverse of the dismantling procedure noting the following:

Tank

When assembling the tank to the pump body use a Studlock adhesive when replacing

the tie bar nut (50).

Relief valve

Place the steel ball (37) in the port then screw in the release valve body assembly (36,

38, 39, 41, 42) remembering the copper washer (4).

Note: If the relief valve seal (35) has been changed or there is doubt about the relief

valve pressure setting, this must be checked when unit is finish assembled. The relief

valve is set at 5000 lbf/in2

and is adjusted by releasing the locknut (39) and turning the

grub screw (40) using a 5mm hexagonal wrench clockwise to increase pressure and

anti-clockwise to decrease pressure.

Main Pumping Piston

Insert O’rings (53, 54) and screw in the piston housing into the pump body. Replace the

main piston (44) carefully pushing and turning into the piston housing. Do not hit the

end of the piston.

Linkage

Connect the lever support (7) to the piston with pin (1) and circlips (8). Do not over

stretch the circlip when fitting. Place the 2 connecting levers (25) into the lever support

(7) and fit the second pin and circlip. Connect the levers to the bracket using the bolt

and nut (26, 27). Carefully tighten making sure the levers are free to move in the

bracket.

Gauge Assembly

Reconnect the gauge assembly, ensuring it does not foul on the tank return pipe. 10

RELAY VALVE RV7: Refer to page 20

Note. Before disconnecting or attempting to remove the Relay Valve, release the system

pressure by operating the Relay Valve lever, then drain the feed tank by disconnecting

the 12mm pipe to the starter and pumping the Hand Pump, collect the fluid in a clean

container for re-use.

ACCUMULATOR: Refer to page 21

Note. Before disconnecting or attempting to remove the Accumulator, release the

system pressure by operating the Relay Valve lever, then drain the feed tank by

disconnecting the 12mm pipe to the starter and pumping the Hand Pump, collect the

fluid in a clean container for re-use.

FILLING AND VENTING THE SYSTEM

After mounting and connecting the various units, fill the Feed Tank with approved

hydraulic fluid to the indicated level.

Pull the Relay Valve operating lever to the fully open position and operate the hand

pump gently until the starter racks have engaged the pinion and then completed their

travel – about ¾ turns of the engine crankshaft.

Release the Relay Valve lever, thus allowing the fluid to be returned to the feed tank by

the spring loaded starter racks.

Allow air to vent from the returning fluid, repeat as necessary until returning fluid is

free from air. Check the feed tank level and top up as necessary.

If the hand pump fails to deliver fluid, it will be necessary to vent it by slackening the

gauge union a couple of turns and operating the lever until fluid emerges free from air

bubbles. Retighten the union and resume venting.

Note:

Where an application has the starter unit positioned above the level of the feed tank it

will be necessary to vent the starter at the two rack connections to ensure that there is no

air in the starter unit. It is not recommended that the starter unit be fitted above the

level of the feed tank for this reason.

Do not attempt to vent the system by removing or disturbing the relief valve.

The system is self-venting in service if laid out as we recommend, and further venting

should only be necessary if pipe runs have been disconnected, or the starter set is

operated with insufficient fluid.

If the starter fails to engage properly or disengages during operation, this may be due to

air in the system, and it should be vented as described.

When checking the fluid level in the Feed Tank make sure first that there is no pressure

in the system, by operating the relay lever valve. PIPE CONNECTIONS

Use only the correct size and specification of seamless, ductile, high-pressure quality of

steel pipe, and the correct fittings as supplied by Prestolite.

Three sizes of pipe are used in the starter system.

6mm diameter: Connecting the hand pump to the relay valve and accumulator

assembly.

10mm diameter: Connecting feed tank and relay valve, and two high pressure pipes

on starter unit. Minimum inside radius of bend 38mm (11/2′′).

12mm diameter: Connecting relay valve to starter unit. Minimum inside radius of

bend 51mm (2′′).

IMPORTANT:

Always make sure that metal filings, burrs and dirt are removed from pipes and unions

before fitting to the system, especially when new pipes have been made, or existing

pipes modified.

Cut the pipe to the correct length and square to its axis. Remove burrs by lightly filing,

without chamfering the outside diameter. Roll cutters are not advised, as they tend to

close the end of the pipe, cause heavy burrs and may damage the sealing diameter.

Clean and oil or grease all surfaces of the pipe, union body, nut, collet “O” ring etc.

11ROUTINE MAINTENANCE

Weekly

Operate Starter. Inspect for oil leaks at all unions. Where leaks are apparent check

whether they are from the pipe “O” ring or coupling washer.

Refer to page 2. Safety Precautions

Leak from pipe “O” ring.

Leak from coupling washer. Slacken union nut while holding the coupling body, tighten

coupling body, and retighten union nut.

If leakage still occurs, replace the coupling washer.

Monthly

Check fluid level in feed tank, and add fluid if necessary.

Grease the relay valve lever pivot.

Check all mounting nuts and bolts, especially those fixing the starter unit, and tighten as

necessary. Renew any broken or missing spring washers.

Fault Possibly Cause Suggested Check & Remedy

1. Starter operates

but does not turn

engine.

1. Worn or broken teeth

on engine dog or

pinion.

Remove starter unit check engine

dog and pinion, and replace as

necessary.

2. Pinion advance

mechanism worn or

jammed due to dirt,

burrs or broken

springs.

Remove starter unit, strip end

covers, spring-loaded balls and

pinion. Examine, clean, deburr

helical grooves or fit new parts as

necessary.

3. Air locks in fluid

system

Vent starter system.

4. Use of wrong fluid of

too high viscosity.

Drain system, refill with correct

fluid and vent.

5. Starter misaligned. Remove starter unit and check

alignment position of mounting

bracket.

6. Relay valve plunger

worn allowing fluid

to leak to feed tank

when relay valve is

operated.

To check, remove air breather.

Operate hand pump, oil should

not return to feed tank until relay

valve lever has been released.

Replace relay valve.

Quarterly

Remove starter unit front cover, and check free movement of racks. Hold relay valve

lever at fully open position and operate the hand pump. The starter pinion should move

slowly into engagement with the engine dog, then rotate about three quarters of a turn.

After releasing the relay valve lever the pinion should rotate freely and return to its

original position. On completion of its return, a distinct click should be heard as the

spring loaded location balls re-engage with the helical slots of the pinion. Failure of the

racks to return may be due to accumulation of hard grease or dirt in the centre housing

or on the rack and pinion teeth. Strip, clean, and adjust as described in the SERVICING

INSTRUCTIONS. Page 5.

Remove feed tank air breather, wash in clean fuel oil and refit.

In very dusty conditions the feed tank air breather may require cleaning more

frequently.

TROUBLE SHOOTING CHART

1314

TROUBLE SHOOTING CHART

Fault Possibly Cause Suggested Check & Remedy

2. Starter does not

operate.

1. Insufficient fluid

pressure. Lack of fluid.

Operate hand pump to increase

pressure. Check and top up

level.

2. Loss of residual gas

pressure from

accumulator.

Operate relay valve to

discharge oil pressure

completely.

Operate hand pump. Pressure

gauge should register about

200 bar (2900 lbf/in2

) for

standard accumulator, after 3

or 4 strokes of the hand pump

with fluid system vented

correctly.

Replace accumulator.

3. Rack seals in starter unit

leaking.

Indicated by sudden leakage

from starter unit. Replace seals.

4. Relay valve plunger

worn.

Proceed for fault 1.6.

3. Starter operates

but racks do not

return.

1. Broken rack return

springs.

Possible if springs are badly

corroded. Fit new “greased”

springs.

2. Incorrect adjustment of

racks.

Adjust as described in

servicing instructions.

3. Relay valve plunger

stuck.

Replace relay valve.

4. Pinion stuck. Proceed as for fault 1.2.

4. Inability to

pressure system.

1. Hand pump not vented. Lever will lack resistance

during pumping. Vent as

described under “filling and

venting system”.

2. Lack of fluid. Check feed tank fluid level.

Top up as necessary. Check

system for leaks.

3. Insufficient flow of fluid

to hand pump.

Clogged filter. Remove filter

and clean as described in

servicing instructions. 15

TROUBLE SHOOTING CHART

Fault Possibly Cause Suggested Check & Remedy

4. Continued. 4. Hand pump valves or

seals leaking.

No resistance to pumping

Bottom suction valve (22),

remove clean and refit

Low resistance to pumping.

Main piston seal (34) or

relief valve leaking, operate

lever to full stroke. If it

returns, main piston seal is

leaking, if lever remains

stationary, relief valve is

leaking.

Dismantle inspect and

replace seals.

Set relief valve to correct

pressure (5000 lbf/in2

5. Relay valve assembly

leaking.

Replace relay valve.

5. Cannot reach

required

pressure.

1. Lack of fluid. Proceed as for fault 4.2

2. Hand pump relief

valve leaking or set

low.

Proceed for fault 4.4

3. Hand pump main

piston lower seal (34)

worn.

Symptom similar to leaking

relief valve. Proceed as for

fault 4.4. Examine and

replace seal.

4. Pressure gauge faulty. Check against accurate

pressure gauge. Replace if

necessary. 16

TROUBLE SHOOTING CHART

Fault Possibly Cause Suggested Check & Remedy

6. Loss of pressure

after charging

system.

1. Leak from hand pump

check valve, or relay

valve assembly

Remove check valves, clean

and replace.

Replace relay valve.

2. Leak from unions,

pipes

Examine system for external

leaks and cure as appropriate.

3. Accumulator losing

gas charge to

atmosphere.

Proceed as for fault 2.2. After

checking accuracy of pressure

gauge. Replace accumulator.

7. Oil blows out of

hand pump tank

breather after

releasing relay

valve.

1. To much fluid in tank. Check fluid level. Should be

50mm from the top of the

tank.

2. Accumulator losing

gas charge to fluid

system.

If fault persists after venting,

replace accumulator.

8. Fluid leaking

from main

piston.

1. Damaged large main

piston seal (36).

Replace Seal

Item Kit Contents B35G8 B50G53 Item Kit Contents B35G8 B50G53

1 Not Available 22 Circlip 47920235 47920253

2 Not Available 23 Retaining Washer 47920235 47920253

3 Pinion ** 527/6 526/599 24 Spring Guide 47920235 47920253

4 Spring Cup 47920235 47920253 25 Spring Outer 47920235 47920253

5 Spring 47920235 47920253 26 Spring Middle ---- 47920253

6 Steel Ball 47920235 47920253 27 Spring Inner 47920235 47920253

7 Spring Plug 47920235 47920253 28 Retaining Plate 47920235 47920253

8 Grovelock Pin 47920235 47920253 29 Washer 47920235 47920253

9 Not Available 30 Coupling * (1) 47920235 47920253

10 Cylinder Cover 47920235 47920253 31 Pipe Small Bend 47920235 47920253

11 Joint Washer 47920235 47920253 32 Pipe Large Bend 47920235 47920253

12 Cover Nut 47920235 47920253 33 Tee Piece * (1) 47920235 47920253

13 Washer ---- 47920253 34 Shim 0.4 ** 527/57 526/233

14 Adjusting Screw 47920235 47920253 35 Engine Dog ** 527/4 526/148

15 Spring 47920235 47920253 36 Capscrew **

16 Rack ** 527/124 526/718 3/8 BSF 311/608 311/608

17 “U” Seal 47920235 47920253 36 Capscrew **

18 Backing Ring 47920235 47920253 3/8 UNF 313/608 313/608

19 Cylinder ** 527/28 526/130 36 Capscrew **

20 Stop Washer 2.4 47920235 ---- M10 381/1025 381/1025

Stop Washer 3.8 ---- 47920253 ND Pipe S29 Long 527/134 ----

21 Circlip 47920235 ---- ND Pipe S29 Short 527/133 ----

(1). For assembly instructions see page 5 18

C D

B A

A B

1:4 Scale: 21/07/2003 Date Modified: Rev. 1.1

9 10

39 38

Hand Pump

Part No. 6518-3519

3 2 1 4

5 8 6 7

1 2 3 4 5 6

Rev.

Service Kit 'LEVERISM' 6518-29

Service Kit 'PRESSURE GAUGE '6518-28

Service 'SEAL KIT' 6518-39

Service Kit 'PRESSURE GAUGE' 6518-28

Pos. Qty Description Mat. Identif. Note

28 1 Banjo Couplings TN1318LR 1-4" for Tube ø8

29 1 Tube 10241F2-16 Tube ø8

30 1 Fit t ings TN1038L 1/4" Gas

31 1 Pressure Gauge 0-400 Pressure Gauge ø 63

32 1 Washer Washer øi8

Service Kit 'LEVERISM' 6518-29

Pos. Qty. Description Mat. Identif. Note

1 2 Pin Fe37A Uni 5334/64 10001-15 Zinc Plated

7 1 Handle Cast I ron 10008-17

84 S.a. ø8

25 2 Arm Fe 37A Uni5334/64 10034-14

26 1 Screw T.E. Fe 37A Uni5334/64 Screw T E M8x35 M8x35

27 1 Nut Nut A-M8 M8

Service 'SEAL KIT' 6518-39

Pos. Qty. Description Mat. Identif. Note

19 1 Seal csc 83 Viton

33 1 Seal csc 3543 Viton

34 1 Seal csc 2014 Viton

35 1 Seal Or 108 Viton

46 2 Seal Or 4350 Viton

53 1 Seal Or 3106 Viton

54 1 Seal Or 146 Viton

Service Kits for

6518-35

21/07/2003 Date Modified:

Seeger ring20

RELAY VALVE RV7 - IS SERVICED BY REPLACEMENT 21

WARNING

Do not attempt to dismantle nor flame cut the accumulator. It is permanently charged with

an inert gas at high pressure, and is service by replacement.

UNAUTHORISED DISMANTLING CAN HAVE FATAL RESULTS

When accumulators are being disposed of, it is important to release the residual gas charge

from the unit beforehand using a standard charging kit.

STANDARD ACCUMULATOR – IS SERVICED BY REPLACEMENT

Part Number: 6518-24

Residual Pressure

200 bar

(2900 lb/in2

)

Sealing Washer 113/45 fitted between

Accumulator and Relay Valve

Supplied with each Accumulator 22

PIPES FOR PANEL MOUNTED ANCILLARIES

SINGLE ACCUMULAOR SETS

Pipes 1 & 2 are supplied

In service kit 6518-26

1. Relay Valve to Feed Tank

10mm Diameter - 6518-3

2. Hand Pump To Relay Valve

6mm Diameter - 6518-4

Hand Pump To Relay Valve

6mm Diameter - 6518-4

Relay Valve to Feed Tank

10mm Diameter - 6518-3 23

Service Notes 24

Service Notes 25

Service Notes The following engines have been fitted with

Prestolite Handraulic Starters

Publication No. ST4MPrestolite Electric Ltd - Heavy Duty Systems Larden Road Acton London W3 7SX

Telephone: 020 8735 4500 Fax: 020 8743 6508

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