1. Fill the master cylinder with fuel oil.
NOTE: When the accumulator is charged to
2. Loosen the hose fitting at the Hydrostarter control
3000 psi and all hoses are filled, there
should be enough hydraulic fluid remaining
3. Actuate the master cylinder pedal until all of the air is
in the reservoir to completely cover the
discharged from the system and a solid stream of fuel
screen in the bottom of the reservoir.
oil is being discharged with each stroke.
NOTE: Replenish the fluid in the master
cylinder as required during the purging
A by-pass valve is located on the inlet side of the hand
pump. Loosen the lock nut and rotate this valve
approximately one turn counterclockwise with a screw
4. Tighten the hose fitting and check for leaks.
driver. Operate the hand pump for 12 to 15 complete
strokes. Do not pump too rapidly. Close the by-pass
LUBRICATION AND PREVENTIVE MAINTENANCE
valve tightly and tighten the lock nut.
Inspect the system periodically for leaks. Primarily,
1. Move the starter control lever to engage the pinion
examine the high pressure hoses, connections, fittings
with the flywheel and open the control valve. While
and the control valve on the starter. Make certain that
holding the lever in this position, operate the hand pump
the oil level in the reservoir is sufficient to completely
until the starter has turned several revolutions. Close
cover the screen at the bottom of the tank. Make this
the control valve. Loosen the swivel hose fitting at the
check after the accumulator is charged and the engine
discharge side of the engine-driven pump about two
driven pump is by-passing oil to the reservoir.
turns. Operate the hand pump to force air out until oil
begins to appear at the loose fitting. Tighten the swivel
Every 2000 hours, or as conditions warrant, drain the
hose fitting and pressurize the system with the hand
reservoir and remove the screen. Flush out the
pump sufficiently to start the engine.
reservoir and clean the screen and filler cap. Then
Perform the initial starting instructions under
reinstall the screen.
Preparation for Starting Engine First Time. Then, with
the engine running at least 1500 rpm, purge the engine-
Remove the bowl and element from the filter in the
driven pump of air. Break the hose connection at the
engine-driven pump supply hose. Wash the bowl and
discharge side of the engine driven-pump until a full
element in clean fuel oil and reassemble the filter.
stream of oil is discharged from the pump. Connect the
hose to the pump and alternately loosen and tighten the
Release the pressure and drain the remaining hydraulic
swivel fitting on the discharge hose until the oil leaking
fluid from the system by disconnecting the hoses from
out, when the fitting is loose, appears to be free of air
the Hydrostarter components. Then reconnect all of the
bubbles. Tighten the fitting securely and observe the
pressure gage. The pressure should rise rapidly to the
accumulator ptecharge pressure (1250 psi at 70"F.),
CAUTION: The oil pressure in the system
then increase slowly, reaching 2900 to 3300 psi.
must be released prior to servicing the
3. After the pressure has stabilized near 3000 psi,
Hydrostarter motor or other components to
examine all of the high pressure hoses, connections and
fittings for leaks.
prevent possible injury to personnel or
4. The engine-driven pump must by-pass oil to the
reservoir when the accumulator pressure reaches
29003300 psi. To determine whether the pump by-pass
NOTE: Make sure all hoses and fittings are
valve is operating properly, remove the reservoir filler
clean before any connections are made.
cap, disconnect the pump by-pass hose at the reservoir,
and hold the hose over the open reservoir filler spout.
Fill the Hydrostarter system with new clean fluid.
An occasional spurt of oil may be emitted from the hose
prior to by-passing. When the by-pass valve opens, a
full and continuous stream of oil will flow from the hose.
Reconnect the hose to the reservoir and install the filler
Remove the Hydrostarter from the engine every 2000
hours for lubrication. Before removing the Hydrostarter,
5. Fill the reservoir to the proper level.
release the pressure in the system by means of the
relief valve in the hand pump. Then remove the
The Hydrostarter remote control system.
purged of air as follows: