* Lucas Bryce f = E Handraulic Starters | © c/s) er — = oe) eT = = cv —_] —— <_ c~> — xO _ — cvCONTENTS Introduction Approved hydraulic fluids and greases Safety precautions Working principles & operating instructions Servicing Starter unit Handturning equipment Miscellaneous items Hand pump Relay vaive Accumulator Pressure gauge Feed tank Automatic charging pump unit ‘Automatic charging pump cambox Pipes for panel mounted ancillaries Handraulic Starters Information Spare Parts Lists ' _ 1 _ 2 - a i a _ 5 a 7 2 _ 2 8 23 8 24 2 8 " 26 " 26 . u x 13 27 _ 28 . ~C) INTRODUCTION This handbook is provided to help the operator to obtain the best service from the Lucas Bryce Hendraulic 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 ie 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 Lucas 8ryce Parts and epproved Hydraulic Fluids and greeces in the Starter installation. The use of spurious parts or incci rect fluids may Cause failures, and will invalidate warranty claims arising from their use. Approved Hydraulic Fluids ard Lubricating Greases: For operation in temperatures below -10° only fluids conforming to specification M15 are suitable, and the following brands are approved: Lucas Bryce only supply fiuid conforming to specification OM15. BP Aero Hydraulic fluid No 1 Mobil Aero Hydraulic Oil HFA Castrolaero 5858 Regent Aircraft Hydraulic Oil 55 Castrol Hyspin AWH 15 Shell Aeroshell No41 Esso Univas J43 Lubricating grease Shell Alvania RA.R2 For operation in temperature above -10” fluids conforming to specification OM13 and OM15 are suitable. The following brands conforming to specification OM13 are approved: BPHL40 Mobil Shock Absorber Oil~ Light Castrol Hyspin AWS 15 Regent Caltex Capella Oil AA Ouckhams Zeroflow 2 Donax At Germ Lubricants Kineticol 1A, Shell Diala Oil B, Tellus T Oil 17 Utility Oil or Nuto H32 Lubricating grease. Castrol Sphero! ‘L’. Shell Alvania RA.R2.Figure 1 Lucas Bryce Handraulic Starter System Layout Feed Engin Tank Bog Hydraulic |L Accumulator Accumulator i Piston Pressure Operating Lever Auto Charging Pump. Starter Unit Hand Pump SAFETY Detailed notes are included in the Operating and Servicing Instructions where appropriate, and are summarised below: SAFETY PRECAUTIONS 1 + De not disconnect pipe joints with the system under pressure. Discharge the accumulator first by operation of the Relay Valve. 2 Donotoperate the starter unless the starter unit is secured to its mounting bracket on the engine. Dx 1g starting the starter pinion is fed forward and rotated at high speed, and the engagement teeth can inflict severe injury. 3 Donot 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 to flame cut the accumulator. permanently charged with nitrogen gas at high pressure. 5 If the accumulator is to be scrapped, before disposal release the nitrogen Pressure as described on page 25. 6 Donotuse lubricating oil or vegetable base oil (such as automobile brake fluid). Use only the hydraulic fluids recommended on page 1.©) WORKING PRINCIPLES AND OPERATING INSTRUCTIONS The Lucas Bryce 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 Hydraulic Accumulator Hand Pump Relay Valve Pressure Gauge Starter Unit Engine Dog Connected by high-pressure steel tubing. {The engine driven pump is an optional extra’ The starter unit is attached to the free end of the engine oy a mounting bracket, and the engine dog is attached to the crankshaft using a suitable adaptor. The heart of the starter is the Hydraulic Accumulator, which comprises a cylinder closed at each end, in which a leak-proof pistons free to slide. Above the piston the cylinder is pre-charged with nitrogen to a pressure of approximately 200 bar {2900 Ibffin2) and permanently sealed. Under this condition 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 untit the piston has been displaced Sutjiciently to raise the nitrogen and fluid pressure to approximately 310 bar (4500 Ibfrin?). 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 corresponcing teeth, which is attached to the engine crankshaft ‘Two helical grooves formed in the periphery of the pinion are engaged by spring foaded 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. Ifthe engine has not been started since leaving the Manufacturers works check the Starter and Engine for freedom as described on page 19. ROUTINE MAINTENANCE Check that the Feed Tank is filled to the correct level with approved hydraulic fluid. Raise pressure to between 276 and 345 bar. (4000-5000 Ibffin2) using the hand pump. Pull the Relay Valve operating lever until resistance is felt (about 45°), then gently but firmly overcome this resistance and apply a continuous steady movement until the lever has reached its stop. The Relay Valve lever operates a two-stage valve, and should not be snatched or jerked.To withdraw the pinion. Ifthe purpose of dismantling is solely to change the pinion, refer now to reassembly 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 (46 mm/1.81" — 835, 64 mm/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 darnage, 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 that leakage has been occurring past the inner sealing lip. ‘The PTFE backing ring should be replaced if the thickness is below 1 mm for 835 or below 2 mm for B50. small fringe which may form on the back face should be cut off carefutty 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. Incorrect assembly will cause premature failure. Figure 3 Assemble Backing Ring with Chamfer this side Ends of Backing Ring butted thus 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 the bores are scored, rough or rusty. (3©) 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 sfide, 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, Putthe steel balis 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 2.5 + 0.2mm from the starter mounting flange to the tops of the pinion 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 TURNING EQUIPMENT B35G8S9 and B50G53S1A The following instructions apply to both of the above units, differences being covered in the text. Refer to page 22 for illustration. Dismantling Remove the front cover (15) complete with the circlip, washers and bush (11-14). Remove circlip (8) and withdraw washers and spring. Support the starter unit on the front face of the centre housing on the open jaws of a vice so that the dog (2) rests on the inside face of the pinion, and the shaft (3) hangs free. Remove circlip (5). Using a soft metal drift (9 mm diameter for 835, 14 mm diameter for BS0Mtap the shaft through the dog.Note. On 835 the drive between shaft and dog is taken by four inclined dowels, one being offset from equal spacing. The dowel holes are drilled on assembly, the dog and shaft only being replaceable as a mated pair. On B50 a single key is used, and the dog, or shaft may be replaced individually. Retain dowels or key. Assembly Clean and dry all parts and replace any which are damaged or otherwise unfit for use. Lightly smear alt parts with grease. Grip the shaft firmly by the square end in a vice, and thread the starter unit over it, mounting flange uppermost. Refit the dog to the shaft taking care to align the dowel holes on 835, or keyways on 850. The boss of the dog should be level with the lower side of the circlip groove. Tap home the dowels, or key until flush with or just below the circlip groove, and refit the circlip, Remove starter unit from vice. Refit spring washers and circlip (7-10) to the shaft, Screw on and tighten front cover. HAND PUMP HP3 Refer to page 23. Dismantling Discharge and Suction: Valves Grip the pump mounting flange securely in a vice. Unscrew coupling (15) from discharge valve seat (12! taking care not to lose the spring and steel ball (14, 13). Unscrew discharge valve seat (12). This will expose the suction valve assembly which can be removed with a suitable screwdriver. The ball can be removed after pushing out the small pin. Relief Valve Unscrew relief valve cover (10) and remove spring, shims, thrust pin and steel ball (9, 8, 7, 5). Unscrew valve seat (6). Piston Washer and Gland Unscrew valve chest (19) having first removed the Discharge and Relief Valves as described above, otherwise they will foul the pump housing when the vaive chest is rotated. The pump cylinder is screwed into the valve chest and will be withdrawn at the same time, leaving the piston in position. Unscrew cylinder (22).Undo screw (25) and remove piston washer (24) Remove spring, gland ring and gland (26, 27, 28) from the housing. Lever and Piston Remove four screws and cover (38, 37). Remove two pins (34) and fulcrum (2), retain washers (36) for reassembly. Withdraw pump lever (31) complete with finks and pins (29, 32, 33). Remove’split pins (30) to enable links and pins to be separated. Wash and dry all parts and replace any which are worn, damaged or otherwise unsuitable for re-use. Pay particular attention te wear of the fulcrum pin and linkage, also to the gland and piston seal. >oO Assembly Fit cylinder to valve chest, taking care that washer (21) is located correctly. Tighten cylinder firmly. Locate washer (20) in recess in pump housing, screw in valve chest/cylinder assembly hand tight only. The tapped hole for the discharge valve should be within 90° — 120° anti-clockwise from its final position (at right angles to the pump base). Note washer (20) is available in thicknesses of 1.0, 1.5 and 2.0 mm to enable this, alignment to be adjusted. Remove valve chest. Grease link pins and links and refit them with the piston to lever, on the same side as the <*2> welded to the lower end. Pass piston through housing bore from the cover end. Slide washers (38) each side between lever and housing, grease and push fulcrum into position, aligning the two holes with those in the housing. Secure with dowel pins (34). Pack linkage with grease and refit cover and screws (37, 38). With the housing held vertically, place gland, gland ring and spring overthe piston and ensure that the gland seats correctly in the housing. Fit piston washer to piston and tighten screw. Grease lightly. Locate washer (20) (thickness previously determined) in recess in pump housing and lift lever to its fullest extent while taking care that the piston washer does not foul the threads in the pump housing. Pass the cylinder over the piston taking care to avoid damage to the piston seal, and screw the valve chest into the housing. Tighten until the taped hole for the digcharge valve is in line with the pump lever. Check for full movement of the pump lever. Refit suction valve washer and assemble, tighten firmly. Refit discharge valve washer and seat and tighten. Drop steel ball into seat and with a soft metal drift, tap lightly to seat the ball. Assemble discharge valve spring, washer and coupling body. Insert relief valve washer and seat into the valve chest and tighten securely. Drop the steel ball into its seat and seat it as described for the discharge valve. Note: If the relief valve is being reassembled to a pump mounted vertically, it is necessary to hold the ball in place with a dab of clean grease. Assemble thrust pin, ensuring that its end protrusion locates the ball in its seat. Fit * original shims, spring, washer and relief valve cover and tighten. If any of the relief valve parts (4-10) have been changed or there is doubt about the relief valve Pressure, this must be checked against a master pressure gauge and reset as. necessary to 345 bar (5000 Ibfiin”). RELAY VALVE RV7, RV8, RV9 Refer to page 26. Note. Before disconnecting or attempting to dismantle the Relay Valve, release the system pressure by operating the Relay Valve lever, then drain the Feed Tank by disconnecting the 12 mm pipe to starter and collect the fluid ina clean container for re-use On sets with isolating valves, RV9, open both isolating valves before releasing the system pressure.Dismantling To renew plunger seal Remove bolts and washers (18, 19) and withdraw lever support complete with lever (12, 13). Pull out the exposed plunger and spring (9, 11) and take care notto damage the fine finished diameter of the plunger. Remove seal (10) using a hooked tool. Insert new seal, with the sealing lip facing inwards. Avoid tilting, and press in flush with end of brass body. Check that plunger is free to slide over its entire travel, any jamming probably means that dirtis trapped between plunger and body. Grease spring and head of plunger, and place in position, with lever support and lever, and secure with bolts and washers. Check that the spring returns the lever to a vertical position when it has been ‘operated, ‘To remove valve assem! Unscrew guide and remove with washer and spring (2,3, 8). Pull out valve assembly {6) using long nose pliers and gripping on the steel stem, Avoid damaging the sealing edge or guide flutes of the brass body. While this valve is only supplied as an assembly, it can be disinantled by ‘unscrewing the brass body from the steel stem. Remove the spring, stop and ste! ball. Wash thoroughly and check that the bleed orifice drilled in one flat of the body is clear. Replace the ball and tap it to ensure a good seat. Replace the sto, squicre portion against ball, the spring, screw on the steel stem and tighten. Refit the valve assembly to the Valve Chest, replace spring, washer and guide and tighten. Ball lift 20-25 mm. {tis not normally necessary to separate the Valve chest (1), guide (7) or body /9). Ifnew washers 4,8) are fitted, allow 1 to 2 flats of the hexagon on each washer from hand tightness to reach the required final position, Isolating Valves fitted to Relay Valve RV9. Dismantling The isolating valves permit each accumulator to be sealed independently. Before removal, ensure that both have been opened and the system de-pressurised and drained as described above. Remove nut, washer and handwheel (15, 33, 34). ‘Slacken nut (32) sufficient to allow a spanner to unscrew valve body and washer (29, 28) from elbow (26). Remove nut (32) completely, and unscrew seat and spindle assembly (27) from the opposite end, Withdraw seal retaining washer and two ‘U’ seals, taking care to avoid damaging the sealing lips. If the seat on either the seat and spindle assembly, or the elbow is damaged we recommend renewing the damaged part rather than trying to reface it. Damage to the elbow is rare. In the event that a new elbow is to be fitted, remove accumulator first, fit anew washer (4) and allow 2 to 3flats of the square from hand tightness to reach the required position.Wash all parts, and with a fine file remove any burrs and sharp edges from the square and the adjacent shoulders of the spindle, so that it can be fed through the ‘U' seals without damaging them Assembly Lightly grease two 'U' seals, carefully feed them into the valve body and pushthem. home using the seal retaining washer. Fit the nut loosely. Grease the square of the valve spindle and push it carefully, with slow rotation into the valve body until it has cleared the seals. Screw it fully into the body. Refit the body and spindie, with washer to the elbow. and tighten. Fit but do not overtighten the seal retaining nut, itis not a gland nut. Fit handwheel with washer and nut, leaving the valve ‘open. ~~ PRESSURE GAUGE PIS Refer to page 26, FEED TANK FT9 Refer to page 26 lower figure Little maintenance is required beyond that called for in routine maintenance instructions. Ensure that both seals (12) are in good condition, and that the dust protection band (5) is correctly fitted and not split. Do not overtighten screw (15), nor bolts (17) clamping mounting clips. If leaks occur from feed of retucn pipe washers (21), drain the tank, remove filter asseinbly and fit new washers. Do not overtighten in an attemptto stop leks as this could damage the tank base. Note that feed pipe assembly is fitted to the central boss. AUTOMATIC CHARGING PUMP Refer to page 27. The Pump Assembly comprises a Pump Unit bolted to a Canbox. ‘To separate pump unit from cambox, drain off any oil in the cambox via the leak-off banjo tapping. Grip the cambox in a vice with the pump unit approximately horizontal to prevent loss of parts. Slacken nuts (22) and pull pump unit away from the cambox until the nuts and washers can be removed entirely. Complete the withdrawal of the pump unit, keeping it horizontal, put one hand over the endo retain the tappet and place it on the bench. Fut nuts and washers back on their studs to prevent loss. PUMP UNIT ACS Refer to page 27 upper figure. DISMANTLING Tip out the tappet, spring and two push rads (6, §, 4). Using a handpress, depress the upper spring plate (20) remove circlip (23) from its groove; a hole allows entry of a small rod to push the circlip inwards. When the circlip has been removed release the spring load, remove the assembly from the press. Pull out both dowels (22), it will probably be necessary to grip each in turn in a vice and ta tap the housing to extract them. Lift off housing (21) and puil out the lower spring plate with plunger attached (36, 14, 18). Take care to avoid damage to the fine finished plunger diameter and the sharp corner made by the end face. ay12 Undo and remove sleeve retaining nut (15) 19 mm (¥") A/flats. The sleeve is now retained only by two '0' rings seals, and it can usually be removed by jarring the top face of body (1) against a hardwood block, or by use of a slow tapered brass drift made to fit the 6 mm bore. If these means are not successful, the sleeve can be removed by applying fluid pressure. Blank both the inlet and discharge unions, and with the body vertical, pour hydraulic fluid into the cylinder and the well left by removal of retaining nut (15). Put the piston with spring plate into the sleeve and push it up and down by hand. This will apply pressure to the lower end face and lift the cylinder. If during ‘pumping’, the piston feels springy, this is due to air which can be bled by opening vent screw (24). lf there is no resistance when pushing the plunger, check for leaks at the various unions and blanks. ‘The plunger is released from the lower spring plate by tapping out the transverse pin, 18), Unscrew discharge union (12), pull out spring and valve pin (11, 9). The vaive seat can usually be removed using a tapered brass rod mate ta fit the 5 mm bore, and levering gently with a circular motion. If this does not free the valve seat, an extractor will be required. This may comprise a piece of bar 14-15 mm diameter, tapped M10 x 1 to fit the thread on the valve seat. The flange can be removed if necessary by sliding it away from the circlip, and prising the circlip from its groove. Note that the flange is chamfered one side to abut and force the circlip into its groove. Wash and dry all parts for examination. All seals and joint washers should be renewed during pump overhaul, particularly if there is any doubt about their suitability for re-use. ‘O' rings must be free from cuts, flats and other imperfections. The upper ’O" ring seals on the inner and outer diameters, the lower ‘O’ ring seals on the two side faces. Renew the plunger andsleeve assembly if there are axial scores or scratches in the bore of the sleeve, or the outside diameter of the plunger, which must bea smooth sliding fit when wetted with hydraulic fluid. Plunger and sleeve are replaceable only aya rnated assembly. Renew the delivery valve assembly if the mitre seating of the valve pin or valve seat is ridged or damaged. Check that two push rods are the same length. Springs must be free from corrosion or distortion, and free length not less than shown in table. PartNo. | Description Minimum free length _| 526/312 | Plunger springACS | 8mm (3.357) 526/399 | Tappet spring 47mm (1.85") 526/415 | Valve spring Timm (.43") Assembly Grease two ‘0’ rings, fit one to groove in sleeve taking care not to damage it, and the other on the spigot at one end of the sleeve.Holding the sleeve with this end uppermost, place body over sleeve, and push it home. Screw in and tighten retaining nut. Fit delivery valve and seat assembly, using an undamaged annealed copper washer each side of the flange, faliowed by the spring. Screw in and tighten discharge union. Oil and push plunger attached to lower spring plate carefully into sleeve and check that it slides freely. Grease and place shims and plunger spring on lower spring plate, slide housing onto body and secure with two spring dowels. Make sure that these enter the holes in the body, projection of dowels from sprin.; "-"-sing not to exceed 3.5 mm. Put upper spring plate on plunger spring, depress using hand press or vice and fit circlip to its groove, making sure that it is properly seated before releasing the spring force. Slide flange over the tappet end of housing with the chamfered side facing outwards, and fit circlip to its groove. Grease and fit the two pushvods, tappet spring and tappet, and holding the pump unit horizontal, Secure it to the cambox tightening the two nuts evenly so that the fiange is parallel to the cambox face. Do not overtighten. CAMBOX Refer to page 27 lower figure. Dismantling Having removed the pump unit as described, undo and remove nut and washer (17, 18) and using suitable puller, draw the drive pully G7 coupling from the tapered shaft. Remove Woudruft key (19). Undo and unscrew four bolts and washers (10, 11) which secure each bearing housing, and pull out the bearing housings complete with bearing (6) outer race. If the bearing housings do not pull out, tap the exposed end of the camshaft using a soft metal maflet or drift to move the flange of bearing housing (9) 3-5 mm away from the housing (1) and lever it away using two levers to avoid tilting and jamming it. Remove drive end pearing housing (8) in the same way. Do not attempt to drive the camshaft right through in removing the bearing housings as bearing (3) has only limited lateral clearance from bosses inside the cambox housing. When both bearing housings have been withdrawn, lift out camshaft with bearing (2, 3) and inner races of bearings (6). To remove bearing (3) pull off the inner races of bearings (6) and shims (5) putting these with their respective bearing housings (8.9), remove both circlips (4), and supporting the inner race on a collar (approximately 30.5 mm/1.2" borel, pres: camshaft from the bearing, Wash and dry all parts, taking care to use only completely clean fluid for the ball bearings. Renew any bearing which exhibits any roughness when revolved, or where the balls or ball tracks are pitted, flaked or corroded. Do not clean the bearings by spinning them using compressed air, and after inspection oil them immediately with clean engine lubricating oil SAE 30 grade. Check that the lip of seal (16) is free from cuts or damage andthatit presentsa g continuous regular seating edge. Itcan be pressed out using a shouldered mandrel 116 ‘Side cotet tem 4) nto position separately belore ut ‘An incication of comet assem is ‘given when the rot ofthe ut Covers the last thread as “A = ees ee Assembly 1 Slide the nut (5), collet (4), back-up washer (3) and ‘0’ ring (2) onto theend of the tube, in that order. 2 Push the tube end into the coupling body (1). Make sure that it is square in | the body. Slide the ‘O’ ring and washer along the tube until they are in the counterbore of the body. On large sizesa light tap with the flat of a spanner will help. 3 Slide the collet into position. Tighten up the nut. Steady the coupling toy with a second spanner. ROUTINE MAINTENANCE Weekly Operate Starter. Inspect for oil leaks at al! unions. Where leaks are apparent check whether they are from tise pipe ‘O’ ring, or coupling washer. Refer to page 2. Safety Precautions. Leak from pipe ‘0’ ring, replace ‘O' ring. Leak from coupling washer. Slacken union nut while holding the coupling body, tighten coupling body, and retighten union nut. Ifleakage still occurs, replace the coupling washer. Monthly Clean filter tray in top of Feed Tank by washing in clean fuel oil Check fluid level in Feed Tank, and add fluid if necessary. «>Grease the relay valve lever pivot and hand pump linkage. Check all mounting nuts and bolts, especially those fixing the Starter unit, and tighten as necessary. Renew any broken or missing spring washers. Quarterly Remove starter unit front cover, and check free movement of racks. Hold relay valve lever at full open position and operate the hand pump. The starter pinion should move slowly into engagement with the engine dog, and 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 asthe 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 breather may require cleaning more frequently. TROUBLE SHOOTING CHART Fault Possible Cause Suggested Check & Remedy | 1. Starter operates | 1 Worn or broken teeth Remove starter unit check but does not on engine dog or engine dog end pinion, ana turn engine pinion replace as necessary Remove starter unit, strip end covers, spring loaded jammed due to dirt, | balls and pinion. Examine, burrs or broken clean, deburr helical grooves springs or fit new parts as necessary mechanism worn or 3 Air locks in fluid Vent starter set system 4 Use of wrong fluid of too high viscosity Drain system, refill with correct fluid and vent Remove starter unit and check alignment and position of mounting bracket 5 Starter unit misaligned To check, remove feed tank lid and top tray. Operate relay 6 Relay valve plunger worn allowing fluid to leak to feed tank valve, oil should not return to when relay valve is feed tank until relay valve operated lever has been released. Replace relay valve body, | { 2 Pinion advance plunger seal assembly 718 TROUBLE SHOOTING CHART Fault Possible Cause Suggested Check & Remedy 2. Starter does not | 1 Insufficient fluid pressure. Lack of fluid operate unit leaking | worn 2 Loss of residual gas pressure from accumulator 3 Rack seals in starter | 4 Relay valve plunger | Operate hand pump to increase pressure. Check and top up oil level. Operate relay valve to discharge oil pressure completely. Operate hand pump. Pressure gauge should register about 200 bar (2900 Ibfiin2) for standard accumulator, or 103 bar (1500 Ibfiin#) for short accumulator after 3/4 strokes, of the hand pump with fluid system vented correctly. Replace accumulator. Indicated by sudden leakage from starter unit. Replace seals Proceed as for fault 1.6 | | 3. Starter operates | 3 Broken rack return but racks do not | springs return of racks stuck 4 Pinion stuck | 2:Incorrect adjustment } 3 Relay valve plunger Possible if springs are badly corroded. Fit new ‘greased’ springs Adjust as described in servicing instructions Remove, clean and refit as described in servicing instructions. Proceed as for fault 1.2 | 4. Inabilityto “| 1 Hand pump not pressurise vented system, | 2. Lack of fluid 3 Insufficient flow of fluid to hand pump Lever will lack resistance during pumping, Vent as described under ‘filling and venting the system’ Check feed tank fluid level. Top up as necessary. Check system for leaks Clogged filter, obstructed pipe, insufficient head due to wrong installation of feed tank. Disconnect feed pipe at hand pump and check that * , ~ YTROUBLE SHOOTING CHART Fault Possible Cause Suggested Check & Remedy | feaking leaking required pressur low seal worn valve chest faulty 4 Hand pump valves 5 Relay vaive assembly 5. CannotReach | 1 Lack of fluid 2 Hane pump retief valve leaking or set 3 Hand pump plunger 4 Hand pump leaking between cylinder and 5 Pressure gauge fluid flows freely. Clean supply pipe, check for damage. Replace filter element, raise feed tank. No resistance to pumping, Suction vaive leaking. Low resistance to pumping. Delivery vaive or relief valve teaking, operate lever to full stroke, Ifit returns, delivery valve is leaking, ifiever remains stationary, reliet valve is leaking. Dismantle, inspect and replace valves or sealing washers. Set relief valve to correct pressure. Check that valve assembly slides freely and returns to its seat. Remove damage from flutes. Check that vaive and ball seatings are undamaged. Replace as necessary. Proceed as for fault 4.2 Procecd as for fault 4.4 Symptom similar to leaking relief valve. Proceed as for fault 4.4. examine and replace seal. Symptom similar to leaking relief valve. Proceed as for fault 4.4, Examine and replace washer Check against accurate pressure gauge. Replace if necessary. after charging system | assembly pipes 6. Loss of pressure | 1 Leak fromhand pump ‘or autocharging pump discharge valve, or relay valve 2 Leak from unions, Proceed as for 4.4, 4.5. Examine autocharging pump discharge valve assembly Examine system for external leaks and cure as appropriate 1920 TROUBLE SHOOTING CHART Fault Possible Cause Suggested Check & Remedy 3 Accumulator losing | Proceed as for fault 2.2. After gas charge to checking accuracy of pressure atmosphere gauge. Replace accumulator 7. Feed tank lid blows off after releasing relay valve 1 Inadequate venting of system 2 Accumulator losing gas charge to fluid system Vent as described under ‘filling and venting the system’ If fault persists after venting, replace accumulator Ca n VYSTARTER UNITS B35G8 AND B50G53 “Not supplied with spare starter units, Order Seporetcly. item] Descriation B35G8__| 850653 | [im] Description B35sGs_ | B50GSs 1 | Housing s2799 | 52613 | | 21| Circtip 124/82 2 | FromCover [52715 | 526131 | | 22 Circtip 52720 | 5261120 3 | Pinion 52716 526/539 | | 23) RetainingWasher| 27/23 | 526/144 4 | Spring Cup 527/25 | 52634 | | 24|SpringGuide 52721 [526/143 5 | Spring 82717 | §26/122 | | 25|SpringOuter [52719 526/125 6 | Steet Ball 20077 2008 26 | Spring Middle — — [526124 7 | SpringPlug | S27/108_ | 526719 | | 27|Springinner [527/29 | 526/126 8 | GroverlockPin | 2864/1620 | 2842028 | | 28 |RetainingPiate [52722 — |526/142 9 | EndCover s2727 | 526721 | | 29] Washer 13091K |11362 10 | CylinderCover | 527/128 | 526138 | | 30| Coupling" /428/M1004 | 428/106 11 | JointWasher | 113/47 | 11339 31 | PipeSmallBend |527/131 [526/767 12 | Cover Nut 827/129 | $2628 | | 32| PipeLargeBend |527/130 |526/766, 13 | Washer — | 1138 33 | Tee Piece* yee3 [13803 14 | Adjusting Screw | 527/16 | 526/129 | | 34| shimoa 527/57 {526233 15 | Spring 527727 | 5261123 | | 35| EngineDog 52718 526/148 16 | Rack |s27n24 | 526718 | | 36 | Capscrew 17 | ‘U'Seat 1301107 | 1301110 3aBSF 31v608 —|311/608 18 | BackingRing }rg0/109 | 1307111 | | 36 |Capscrew 19 | Cylinder 527/28 | 526130 UNF 3131608 {313/608 20 | Stop Washer2.3 | 527/18C = 36 \Capscrew M10. | 3811025. [381/1025 Stop Washer2 4 | 527/188 - ND] PipeS29-Long {527/134 ies Stop Washer 2.6 | 527/18A = ND|PipeS29-Shont | 527/133 StopWasher38]} — | 526/138 *For assembly instructions see page 16. 2122 HAND TURNING EQUIPMENT B35G8S9 and B50G53S1A itera] Description | 635G8S9 | B50G53S1A | [Miscellaneous Items (not illustrated) | Part No. | PareN No} PartNo. Pipe, 12mm oidia x 1m 526780 ‘i Pipe, 12mm oidiax 2m 526/788 nee Pipe, 1mm oidiax 1m 526/798 ly se Pipe, 10mm oidiax2m 5267798 comprising 2-5] 527/62 = : Pipe, 6mm oidiax 1m 526/780A 2 1208 226958 | | Pipe, mm oidiax2m 526/780B 3 |Shaft 5 526/222 see : 4 |Dowel suaise — Fleniblepipe, Alpe 237IM15 | 237/M22_ | | 12mm oldia standpipe ends x 380mm| 220/10 alae a 5267159 | | Fiexiblepipe. 7 |Washer s27az | 526/165 ‘i : 3 lena Barre | Zarrie: | | Yommoliastandpipe ends 380mm| 22071 ! 9 |Washer 527142 | 526/157 eae Pes 10 [Spring Beige | SSRIS |_| emmoidiastandpipe ends x 380mm | 220/12 a eee 527/40 | 5261153 | | Through-coupling, 12mm oldiapipe | 431/12 12 |Ciretip 527/41 | 12426 Through-coupling, 10mm o/diapipe | 431/M10 Naleaea eos Through-coupling, mm oidia pipe} 431/M6 14 |Feltwasher | 527/39 | 526/154 igh-coupling, ae 18 |Frontcover | 827/36 | 526221 | | equat.tee 10mmoidia pipe 13837 * Not supplied Equal-tee 6mm oidia pipe 13840 separately Hydraulic fuid Slitee can} Specification OM15 1422 Accumulator clamp assembly 5261690 “0' Ring 12mm oldia pipe 234/115 234/112 0 Ring 6mm oidia pipe | 234/105 C BN CyHAND PUMP HP3 separately [em [ eseroton Part No. tem | Description PartNo. 1 | Pumphousing 526/57 20 | Washer2.0mm 313/42C 2 | Fulcrum 52682 21 | Washer 113/46, 3° | Bush 135/11 22 | Cylinder 526/68, 4 | Washer-seat 52674 23. | Piston 526169 5 | Steetball 2007 24 | Pistonwasher 526/60 3 | Seat-reliefvaive 52686 25 | Screw 526/75 7 | Thrust pin 526/63 26 | Spring 526/89 8 | Shimogmm 526/870 27 | Glandring 526168 8 | Shim0.3mm 526/87B 28 | Gland 526/67 9 | Spring 526/88 29. | Linkpin-small 526164 10 | Relief Valve cover 526/61 30 | Splitpin 206/412 11. | Suctionvalve assy 526/117 31 | Lever 526/280 12 | Valveseat-discharge | 526/72 32 | Link 52679 13° | Steel ball 200/10 33° | Linkpin-large 526/81 4 Spring 526/166 ee Dowel pin 284/1224 18 | Couplings 138/34 35 | Bush 136/10 16 | Washer 52612 36 | Washer 2088 17 | Washer 11383, 37 | Endcover 52665 18 | Coupling azeMiooa | | 38 | Screw 291/610 19 | Vaivechest 526/190 139. | Leverextension 526/83 20 | Washer 1.0mm 113/428 20 | Washer 1.5mm 113/428 ‘Not supplied with spare pumps, order, *For assembly instructions see page 16. 2324 r RELAY VALVES RV7 RV8 RV! O- COMMON TO AV7, 8&9 item | Description Part No. item | Description PartNo. 1 | Valve chest RV7 5265 19 | Washer 107/20 Valve chest RVB &9 526368 20 | Couplings 138/36 2 | Washer 113/46 21 | Couplings 428/M11004 3 | Spring guide 526/32 22 | Coupling’ 428/M1206 4 | Washert.0mmthick — | 113/434 23 | Washer 113/62 1Smmthick — | 113438 24 | Washer 526/12 ZOmmthick — | 113/a3C 25 | Plug 1, 526:22 5 | Spring 526/49 26 | ElbowRve ("526/375 6 | Valveassembly 526/247 7 | Guide 52621 Parts for RV9 only 8 | Washer a} 26 | Elbow 526367 9 | Body, plungersealassy | 526/585 23 | Seat& Spindle assy Sonor 28 | Washer 1139 10 | Seat neues 23. | Valve body 526362 1 | Spring eras 30 | Seal 13071 12} Leversupport 8262 31 | Washer 526/341 13 | Lever 5263 32 | Nut 526/342 ie be aed 33. | Handwheel 526/363, ee eee eae 34 | Spring washer 2054 17 | Krob 4336/1 Pel ece see UNLESS STATED, ALL PARTS ARE, *For assembly instructions see page 16. Cp aSTANDARD ACCUMULATORS _ 122018 eee) warning Pate — Le 528730 Fixing pine ‘reoes Par Standard iong ‘Accumulator Residual pressure, "00 0a? (29008) 96.5014 (378) pas: Standard Supplementary Accumulator comprises — paa Standard short Accumulator Residual oressure, 103 bar (1800 btn”) PAI Accumulator 526471 Adaptor £228:M1206 Stud coupling 52622" Blanking plug Tia Washer 27 Washer J Sealing washer 113:45 fined berwean = ae ee ‘Supplied with each Accumulator WARNING Do not attempt to dismantle nor to flame cut the accumulator. It is permanently charged with an inert gas by high pressure, and can only be repaired by Lucas Bryce 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. This is done as follows: MK1 (Early diaphragm type). Remove the large hexagonal nut from the top of the accumulator. Undo the brass plug now exposed by one to two turns and allow the gas to escape. When the gas has escaped fully, remove the plug completely. If there is no escape of gas when the plug is slackened, this is possibly due to fibre or hard rubber from the seal obstructing the central hole, and it will need to be drilled out. Use a drill about 1.5 mm diameter. When drilling, hard particles will be blown out violently by gas under pressure, and can cause eye injury. Fit a shield of metal or stiff card over the drill, and keep the eyes out of line with the drill MKII MKIIl and MKIV (Late diaphragm type and piston types). Remove the dome shaped cover from the top of the accumulator by prising off, or shearing the three retaining rivets. Slowly undo and remove the socket grub screw and ball. Puncture the rubber flap sealing valve and allow the gas to escape as described for MKI * accumulator, again taking care to prevent eye injury. 2526 PRESSURE GAUGE PIs item| Description | PartNo. 7 [Dial gauge complete | PIS 2| Couptingr | 13836 Een TRC tem| Description | Part No. 1 jTankbody — | Sz6/164a . work 2 | Topway 526/1648 awe 3 ltd 526/163 ; = 4 | Wing nut 13128 5 | Dust protection band 130/74 6 |AirBreather | 526/161 7 | Return pipe assembly | 526770 8 | Feed pipe assembly | 526769 9 |FilterElement | 1481 10 |DistancePiece| 526/aa0 PP, ” 526/433 ws 12 234/110 13 | Washer 2086 14 | Spring ania 15 | Screw 103/14 16 | Clip, oitlevel | 526/676 17 | Bott 10482 18 | Nut 47 19 | Washer 2055 20 | Mounting clip | 526/195 21 | Washer 106/44 *For assembly instructions see page 16. a“ - (7)P Description | PartNo. Pushrod | 528/821 Spring 320809 Tappet §26/329 Wasner | 526/12 Couplings | 428intr004 Valve & Seat assembly | 526424 Wasner’ | toss Spring 526/415 Discherge union 13809 Oring dea Plunger & sleeve assy 526/425 Retaininginut | §26699 Lower spring plate 528093 ‘Spring 526/312 Bowel 2ea510 Shim-gmm | 526/616 20 | Upperspring IP UNIT ACS plate 526/319 21 |Housing ‘| s26/320 Description | Pano | 22 | Seiroipn | 357/808 23 | Giclip 12436 Body 526/698 | 24 | Airventscrew | 1/126 Fange | $2028 | 25 | Washer” | Nwsrra Circlip 15/58 Q—z Them] description | Partno. Sai 7 [Housing 26402 2 \ Camshaft 526/412 3 |Batrece | isaz6 & | Gretp 237iN30 5 |Shim-tamm | 10/1298 aamm | 10/1298 Smm | 10729¢ 6 | Bearing i328 3 [eine 526328 8 | Bearing housing 526/395 9 | Bearing housing 2613 10 | Bot 226008 11 | Washer 10712041 12 |FibreWasher | 1008 13 | Plug T9081 14 | Banjo 51/2838 15 |Banjobor | t5/77 18 [Sealring | 13055 17 Nut gee 18 | Washer 2039 19 | Woodruttkey | 10805 20 | Stud s2ea24 21 | Washer 2058 22 | Nut 226 *For assembly instructions see page 16. a28 PIPES FOR PANEL MOUNTED ANCILLARIES SINGLE ACCUMULATOR SETS LH ASSEMBLY 1, Relay Valve to Pressure Gauge 2. Hand Pump to Relay Valve 6mm DIA LH $2674 6mm DIA LH §26771 4, Feed Tank to Hand Pump 10mm DIA LH 526/773 2. Relay Valve to Feed Tank 10mm DIA LH 526777 PIPES FOR PANEL MOUNTED ANCILLARIES: DOUBLE ACCUMULATOR SETS LH ASSEMBLY 1, Relay Valve to Pressure Gauge 4, Relay Valve to Feed Tank 6mm DIA LH 526793 10mm DIA LH $2670 2. Hand Pump to Relay Valve 5, Relay Valve to Pressure Gauge ‘6mm DIA LH 526788 6mm DIA LH 526792 3. Feed Tank to Hand Pump 10mm DIA LH 26773 {ON SETS WITH ISOLATING VALVES ONLY) >» ?The following engines have been fitted with Lucas Bryce Handraulic Starters Suitable for applications such as compressors, generators, cranes, rail traction, marine and pumping sets. Used extensively by Oil Companies, Military and Government Departments, Ship and Lifeboat-Builders, Contractors and Plant Manufacturers. Engine Bernard Caterpillar Cummins Detroit Diesel (Generat Mocors) Deutz (HD) Dorman Type waa 334 342 343 346 353 3208 3304 3306 3406 3412 va78 v 504 NT 855 220 330 3a: 466 500 53 Series 71 Series FL arg FLSt4 FL FM 716 F.Lai2 BAM 816 FL 912 FL 913 LB Lo Kl 4/6 DA 8DA you as 6a Sune B35G 8506 B50G B50G. 8506 B50G B50G 8506 8506 sod, 8506 835G. 8506 B50G 8356, 8356 506 8506 8506 8356 8506 8506 8506 8506 8506. 8356 8506 8356 8356 8506 8506 8506 8356 8506 B50G B80G, 8506 Engine Fiat Foden Ford Gardner International Isuzu Kubota Leyland @u Lister Man Mercedes Type 081M 8035 cos’ FO 24008 2500 2710E 2800E lw Uo 282 221 KO 22 MKE 490 680 2/3 KA 2/3 HR 4/6 HA 4/6 4R JA aw P © 2542 0 2565 0 2566 om 314 Om 352 OM 355 ‘ou 360 om 401 OM 402 OM 403 OM aoa Starner 8356 8356 8506 8356 8356, 835¢. 8356 B50G 8506 8356 8356 8506 8506 8356 E50G 8256 8356 8506 8506 B50, 3506 8506 8506 8506 BEeC, 8356 8356 8506 8506 BE0G 8506 8506 8506 Engine Mitsubishi Mw, Perkins Peter Rolls-Royce Ruuggerini Scania Volvo Yanmar Type 3F-5S 36-28 Si2N 6020 PTK 226 232 302 323 316 917 4/108 3/152 5/203 4/236 5/354 8510 v8 540 Po PH Ps AVA c si RD 901 ose str os 14 Mo 32 MD 70 MO 100 MO 120 5 KOAL Starter 8356 8506 8506 8506 835G. 8506 B35G 8356 8356, 8356 8386 8356. 835¢ B35G 8356 8506 8506 8506 Bo8G, 8356 8356. 8506 3506 8356 8506 850G 8506 B35c 8506 850G B50G 8506 Many other engines can be equipped with LUCAS BRYCE Handraulic Starters and reference should be made to LUCAS BRYCE Starter Sales for guidanice on the method of installation. Publication No. ST3M 2 ty