Belle Major 30-140 Operating instructions

1
BELLE GROUP WILLERSEY.
MAJOR 30-140 HYDRAULIC POWERPACK
OPERATING AND MAINTENANCE MANUAL
Belle Group Willersey.
Willersey Industrial Estate.
Willersey, Nr. Broadway.
Worcestershire, England.
Issue No.2. Telephone:- [phone]
Date:- NOV 2002 .Fax: [phone]
email [email protected]

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FOREWORD.
This manual contains general information on the operation and maintenance of the Belle Group
Willersey Major Hydraulic Powerpack.
The manual is divided into the following sections :-
1. Description and Specification.
2. Operating Instructions.
3. Maintenance.
4. Parts Lists.
5. Safety.
A comprehensive Contents list follows this foreword.
Information contained in this manual is correct at the date of publication Belle Group Willersey have a
policy of continuous improvement and therefore, reserve the right to make alterations without giving
prior notice.
The contents of this manual are copyright (C) and must not be reproduced without prior permission of
Belle Group Willersey.

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SAFETY PRECAUTIONS.
WARNINGS AND CAUTIONS.
For the purpose of definition in this manual :-
AWARNING (printed in capital letters) gives information which, if ignored, could lead to
ACAUTION (printed in capital letters) gives information which, if ignored, could cause
FOR YOUR OWN PERSONAL SAFETY READ AND TAKE NOTE OF THE FOLLOWING:
EXHAUST GASES : Before starting the engine ensure that there is adequate ventilation to
REFUELLING : Never attempt to add fuel or oil when the engine is running. Use only the
MAINTENANCE : Do not attempt to carry out any maintenance work in the vicinity of the
Before disconnecting any part of the hydraulic system make sure that any

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CONTENTS LIST.
Section/Para.Title.
SECTION 1. DESCRIPTION AND SPECIFICATION.
1.1...............................................................................INTRODUCTION.
1.2...............................................................................DESCRIPTION OF OPERATION.
1.3...............................................................................SPECIFICATION.
SECTION 2. OPERATING INSTRUCTIONS.
2.1...............................................................................PRE-START CHECKS.
2.2...............................................................................STARTING THE ENGINE.
2.3...............................................................................OPERATING CHECKS.
2.4............................................................................. .STOPPING THE ENGINE.
SECTION 3. MAINTENANCE.
3.1...............................................................................INTRODUCTION.
3.1.1..................................................................... .Maintenance Procedure Recommendations.
3.2...............................................................................ROUTINE MAINTENANCE.
3.2.1............................................................................Routine Maintenance Schedule.
3.3...............................................................................FAULT DIAGNOSIS
3.4...............................................................................SYSTEM PRESSURE AND FLOW CHECKS.
3.5...............................................................................REMOVAL AND REFITTING PROCEDURES.
3.5.1............................................................................Frame/Chassis Assy.
3.5.2............................................................................Cowl.
3.5.3............................................................................Valve Block.
3.5.4............................................................................Cooler.
3.5.5............................................................................Pump.
3.5.6............................................................................Fan.
3.5.7............................................................................Engine.
3.5.8............................................................................Power on Demand System.
SECTION 4. PARTS LISTS.
4.1.............................................................................. SPARES HOLDING INFORMATION.
4.2.............................................................................. SPARES ORDERING INFORMATION.
4.3.............................................................................. PARTS LISTS.
SECTION 5. SAFETY.
5.1...............................................................................EHTMA Code of Practice.
ADDENDUM

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SECTION 1 - DESCRIPTION AND SPECIFICATION.
1.1 INTRODUCTION.
The Belle Group Willersey. 30-140 Major Hydraulic power unit has been designed to provide a power
source for a range of accessory tools including Breakers, Pumps, Drills, Disc Cutters, etc., compatible
with EHTMA Category 'D' flow and Pressure.
The power units sturdy yet lightweight design makes it very portable and it will fit into most estate
cars. The stainless steel frame provides convenient handling points and protects the unit. Non-drip
Quick Release Couplings are provided to allow for clean and convenient connection of hoses and
equipment.
The unit is mounted on a substantial steel chassis fitted with two rubber wheels and two rubber feet,
making the unit very maneuverable yet stable when working.
The unit is powered by the reliable Honda GX390 Single Cylinder 4-stroke Petrol Engine. The Engine
and Hydraulic oil systems are fitted with an "Oil.Alert" device to stop the machine if either oil level
becomes too low.

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1.2 DESCRIPTION OF OPERATION.
The Petrol Engine (1) drives the hydraulic pump (2) via a drive coupling assembly. The hydraulic
pump draws oil from the tank (3) via a suction strainer and delivers it to the Valve Block (4) which
incorporates a By-Pass valve to allow oil to circulate round the system when first started. Flow is
directed to the Tool or Equipment via Non-Drip Quick Release Couplings after setting the By-Pass
lever to the flow position.
When the accessory tool or equipment is in operation, oil flows to the accessory and is directed back
through the return line at low pressure, through the Spin-on Return line filter (5) to tank, or via the
cooler (6) depending on the oil temperature which is monitored by the Thermal Valve,
Max pressure is controlled by a Relief Valve fitted into the Valve Block. If the supply pressure
exceeds that set by the relief valve, it operates to direct hydraulic oil back to the return line.
The oil pressure and hence the efficiency of the machine is influenced by temperature, and it is
important that the correct working temperature is maintained. The oil temperature is controlled by a
Thermal Valve, on initial start up the oil is cold and therefore its viscosity is high, The Thermal Valve
directs the oil to tank. until such time as the oil temperature rises to its minimum working level. The
Thermal Valve which incorporates a heat sensitive capsule will now direct the return line oil flow to
tank via the cooler, thereby stabilizing the oil temperature.
Cooling air for the radiator is provided by a fan which is mounted onto the engine shaft and enclosed
by a housing. The radiator is mounted at the side of the housing and is protected by a guard.
A filter condition gauge mounted on the cowl monitors the return line pressure. If the return line filter is
blocked the pressure will rise, and when the indicator needle reaches the red sector under normal
working conditions the filter should be replaced.
The supply line is protected from the ingress of dirt by a Suction Strainer situated in the hydraulic
tank. The Tank also incorporates a Sight Level Gauge and a Float Switch. The Level Gauge provides
indication of oil level,(The correct level being at the top of the sight glass) and the Float Switch
monitors the oil level and stops the engine at the preset low level.
The engine is fitted with an oil sensor, which operates in a similar manner to the hydraulic tank float
switch to protect the engine if its lubricating oil level falls below a safe level.

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1.3 SPECIFICATION.
Engine:- Honda GX390 single cylinder, air cooled. 13 Hp Petrol
Engine Refer to Engine Manual for further details.
Hydraulic Flow:- 30 litres/min. (6.7 GPM) EHTMA Class D.
Working Pressure:- 138 Bar (2000 Psi)
Dimensions:- Height......560 mm
Width.......540 mm
Length.....720 mm
Hose:- 7 metres long Siamese, 1/2" bore.
min. Burst Pressure 828 Bar (12000 Psi)
Hydraulic Oil:- For ambient Temperatures below 32 degrees Centigrade,
use a ISO VG T32 or equivalent.
For ambient Temperatures above 32 degrees Centigrade,
use ISO VG T46 or equivalent.
Fuel:- Petrol (Unleaded).
Tank Capacity 6.5 Litres.
Guaranteed Noise Level:- 104 LWA

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SECTION 2 - OPERATING INSTRUCTIONS.
2.1 - PRE-START CHECKS.
1. Ensure that the power unit is standing on a stable level ground or where necessary that it is
suitably chocked for stability.
CAUTION - DO NOT OPERATE THE POWERPACK AT AN ANGLE GREATER THAN 20
CAUSING EXTENSIVE DAMAGE TO THE ENGINE.
2. Ensure that the engine exhaust is not obstructed and that there is adequate ventilation to
disperse the exhaust gases.
3. Ensure that the transmission hoses are positioned to avoid damage by vehicles etc., and that
they will not be under strain when connected to the accessory or tool.
CAUTION - ENSURE THAT THE INTERCONNECTING HOSE COUPLINGS ARE
DAMAGE TO SEALS.
WARNING - NEVER ATTEMPT TO ADD FUEL OR OIL WHEN THE ENGINE IS RUNNING.
USE ONLY THE CORRECT GRADE AND DO NOT OVERFILL.
4. Check engine fuel and oil level, top up as necessary. Refer to engine manual for details of
grades.
5. Check hydraulic oil level and top up as necessary.
NOTE - WHEN TOPPING UP THE HYDRAULIC TANK, IT IS ADVISABLE TO USE A
STRAINER. DO NOT OVERFILL.

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2.2 - STARTING THE ENGINE.
NOTE - REFER TO THE ENGINE MANUAL FOR DETAILS. ALWAYS ENSURE THAT THE
BYPASS LEVER IS IN THE BYPASS POSITION.
1. Open the fuel tap.
2. Set the start/stop switch to the on position.
3. Set the choke lever to the closed position.
4. Pull rope starter strongly but firmly in a steady action. If engine does not start, allow the
5. Gradually return the choke lever to the open position as the engine warms up.
2.3. OPERATING CHECKS.
Before commencing operations the following checks should be made:-
1. By-Pass lever is in the flow position.
2. Check that there is no excessive engine vibration.
3. Ensure that there are no hydraulic leaks from hoses or couplings.
4. Check that the filter condition indicator is not within the clogging sector once normal
Depending on the ambient temperature, optimum performance should be achieved after 5-10 minutes
operation. This is the time required for the hydraulic oil to reach its correct operating temperature.
2.4 - STOPPING THE ENGINE.
NOTE - REFER TO THE ENGINE MANUAL FOR DETAILS.
1. Set the By-Pass lever to the By-Pass position.
2. Switch the start/stop switch to the off position.
3. Close the fuel tap once the engine has stopped.

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SECTION 3 - MAINTENANCE.
3.1 - INTRODUCTION.
In this section information on maintenance of the power unit is presented in the form of a Routine
Maintenance Schedule followed by a Fault Location Chart, and inspections and specific maintenance
instructions of the power unit assemblies.
3.1.1 - MAINTENANCE PROCEDURE RECOMMENDATIONS.
Before carrying out any maintenance on the power unit note the following recommendations:-
a) The hydraulic components used on Belle Group units are precision made; maintenance of
these components should therefore be carried out by suitably qualified personnel.
b) When servicing hydraulic components, absolute cleanliness is essential. Most hydraulic faults
are caused by the ingress of dirt.
c) Before dismantling a component, clean externally and drain all fluid. All parts should be laid
out on a clean surface and their identification and dismantling sequence noted.
d) All dismantled metal components should be cleaned using a mineral based solvent, dried and
then coated with clean hydraulic oil. Seals should be washed with clean hydraulic oil. It is
recommended that removed seals should be discarded and replaced with new items. Where
a seal is to be refitted it must be closely inspected for wear or damage and if suspect must
not be reused.
e) Do not use pipe wrenches on hose connections, as they damage fittings and protective
plating. Use adjustable or open-ended spanners. When tightening hose connections ensure
that the hose does not become twisted.
3.2 - ROUTINE MAINTENANCE.
The following schedule details the attention considered necessary to ensure satisfactory operation of
the power unit.
NOTE : THE ATTENTIONS AND PERIODS SUMMARISED IN THE SCHEDULE ARE
INITIAL RECOMMENDATIONS AND SHOULD BE REVISED TO SUIT THE
POWER UNIT WORKING CONDITIONS.

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3.2.1 - ROUTINE MAINTENANCE SCHEDULE. RUNNING HOURSITEM. ATTENTION 10 100 300
Complete Unit Keep all areas clean and free
from dust , debris, etc.
Check security of all
fasteners especially on
Engine Mountings.
*
*
Wheels & Feet. Examine for damage. *
Transmission hoses Examine for leaks or
damage.
Check for correct positioning
of protective sleeve. *
*
**
*
*
Engine. Check oil level.
Examine engine mountings.
Examine Exhaust silencer for
damage or deterioration.
Check for excess vibration
when running.
Change Oil/Service. Refer to manufacturers
instructions
Hydraulic Tank Check oil level.
Replace Filter.
Change Hydraulic Oil
**
*
Oil Cooler. Externally clean using
compressed air DO NOT
USE WIRE BRUSH.
*
Return line Filter. Replace or when indicator
showsclogged. *
Hydraulic pipes/ Connections Examine for oil leaks *

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3.3 FAULT DIAGNOSIS.
SYMPTON POSSIBLE FAULT ACTION
Engine stops or will not start Fuel tap switched off.
Fuel shortage.
Fuel line blocked.
Air cleaner blocked.
Engine oil level low. (Oil Alert
Switch)
Hydraulic oil level low. (Float
Switch).
Engine malfunction.
Engine ignition switch or
connecting wires damaged.
Hydraulic tank float switch or
connecting wires damaged.
Hydraulic pump seized.
switch on fuel tap.
Refuel.
Clean filter.
Clean. or renew element.
Refer to Engine Manual.
Top up to correct level.
Top up to correct level .
Refer to engine manual.
Check for earth leak,
Renew worn or damaged
parts. Renew worn or
damaged parts.
Renew pump.
Hydraulic oil pressure low. By-Pass lever in by-pass
position.
Relief valve set low or worn.
Pump worn or damaged.
Engine power low.
Set to flow.
Check relief setting. and
adjust if necessary.
Replace if necessary.
Check system oil flow (re
Para 3.4) Renew pump if
necessary.
Refer to engine manual.
Hydraulic oil temperature too
high. Radiator fins blocked. Cooling fan lose or damaged.
Hydraulic pump worn or
damaged.
Relief valve set low or worn.
Thermal valve malfunction.
Hydraulic oil contaminated.
Clean using air blast.
Tighten or renew as
necessary.
Renew pump.
Check setting & replace as
necessary
Renew valve.
Drain oil tank & transmission
hoses and replenish with
correct oil grade .Renew
filters.
Excessive vibration. Engine misfiring or hunting.
Engine mountings loose. Refer to engine manual. Tighten or replace damaged
parts.
Engine speed remains at idle
when tools are operating. P.O.D. Cylinder seized in retracted position.
P.O.D. Cable Adjustment
incorrect.
Throttle lever set at incorrect
setting
Check cylinder & replace as
necessary.
Re-adjust as necessary.
Reset engine speed & lock
throttle lever using thumb
screw.
Engine speed remains at full
when off load/By-pass. P.O.D. Cylinder seized in extended position.
P.O.D. Cable adjustment
incorrect.
Check cylinder and replace
as necessary.
Re-adjust as necessary.

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3.4 . - SYSTEM PRESSURE AND FLOW CHECKS.
1. Connect a suitable hydraulic test unit to the powerpack. The unit should comprise a high
pressure flowmeter 0-50 l/min, a pressure gauge 0-200 Bar (0-3000 Psi), a temperature
gauge, and a load valve. Suggested unit available from UCC (UC 4120).
2. Connect the test unit to the power pack with the load valve and the By-Pass lever in the by-
pass position and start the power pack. Allow the engine to warm up, set the by-pass lever to
the flow position. Close the load valve completely and check that the relief valve setting is
correct (140 Bar). The hydraulic oil will tend to get quite hot during this operation and
therefore the checking should be carried out as quickly as possible and the load valve
opened before excessive temperatures are reached.
3. Carefully close the load valve to raise the pressure to 100 Bar (1500 Psi). Check that the flow
rate is between 27 and 30 l/min. Adjust the engine speed to give the correct flow. DO NOT
EXCEED 3600 RPM " on load " speed. If correct flow cannot be obtained within max engine
speed then the pump must be suspect; replace as necessary.

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3.5. - REMOVAL AND REFITTING PROCEDURES.
3.5.1. - FRAME/CHASSIS - Refer to Fig 3.1.
a) Remove the four Durlok Screws (Item 9) securing the frame to the chassis (Item 5) and retain
screws. The frame (Item 1) will now lift clear and the wheels are free to slide off their axles if
required.
b) The rubber feet (Item 7) can be removed by undoing the Nut and Washer and withdrawing
the foot from its location.
c) Removal of the Handle (Item 4) should only be carried out when the existing handle must be
replaced due to damage etc. The handle is riveted to the frame using a strong rivet (Item 2)
which is installed at the factory using a special tool. Replacement of these rivets cannot easily
be made without the special tool, and we recommend that this operation is carried out by the
Belle Group Willersey Service Department.
d) The two Universal Mounting Plates (Item 12) can be removed by undoing the Set
Screws(Item 10) and Spring Washers (Item 11). Set Screws (Items 13 & 14) holding the
engine in place would be removed with the engine assy.
NOTE -Reassembly of the Frame/Chassis components is the reverse of the above; it is strongly
recommended that new Spring Washers (Items 11 and 7) are fitted to ensure locking.

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3.5.2. - COWL - Refer to Fig 3.2.
a) Remove the frame as described in 3.5.1. above.
b) Drain the hydraulic oil by removing the Drain Plug (Item 4) and Seal (Item 3).
c) Disconnect the Capillary Tube (Item 16) from the gauge end of the hose and plug to prevent
leakage.
d) Remove the Cap Screw (Item 7) and Washer (Item 8) securing the Cowl to the Valve Block.
e) Remove the 8 off Set Screws (Item 11) and Washers (Item 12) which secure the cowl to the
Tank.
f) Lift away the Cowl from the hydraulic tank in an upward and forward motion to clear the
Q.R.C.Couplings (Fig 3.3. Items 17 & 18) taking care not to damage the gasket (Item 13).
g) Access is now available to the inside of the tank, allowing removal of the Suction Strainer
Item 2), Float Switch (Item 6), and Sight Level Gauge (Item 5) for servicing.
NOTE- It is recommended that a new Gasket (Item 13), drain plug seal (Item 3) and Gauge seal
(Item 15) be fitted upon reassembly.
NOTE - The Tank (Item 1) should not normally require removal from the Chassis unless substantial
damage has occurred. If it is necessary to replace the Tank assy it should be note that the Rivets
(Item 17) used to secure the Tank are factory installed using a special tool and it is recommended
that this work be carried out by Belle Group Willersey Service Department.

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3.5.3. - VALVE BLOCK - Refer to Fig 3.3.
a) Remove the Cowl as described in 3.5.2. above.
b) Disconnect the cooler feed and return pipes by undoing the swivel nuts at the cooler
connections (Item 7 & 8 Fig 3.4) and the Cap Screw and washer (Items 11 & 12 Fig 3.4).
Gently remove the pipes from their locations in the Valve Block.
NOTE - Support the hexagon fitting of the cooler using the correct size spanner to avoid twisting
damage to the cooler.
c) Disconnect the H.P. Feed pipe (Item 19) by undoing the pipe end nuts and gently remove the
pipe.
d) From within the hydraulic tank remove the four Set Screws (Item 25) and Washers (Item 26)
remembering to support the valve block weight. Remove the Clamping Plate (Item 27) and
break away the valve block from the tank wall and remove the Gasket (Item 30), taking care
not to leave the Blanking Plug (Item 28).
NOTE - Should further disassembly of the Valve Block be required the following points should be
noted: -
1) Always refit a new Filter Can (Item 24) remembering to smear the new seal with clean
hydraulic fluid. It is normally sufficient to tighten to a good hand tightness, however the Can
should be checked for tightness once the powerpack has been re-assembled and run to
warm up the hydraulic oil.
If hand tightness proves to be insufficient to seal the Filter Can, a strap wrench may be used
provided that the Can is not distorted.
2) The Relief Valve (Item 11) is a cartridge unit, and should only be removed to examine the
seals fitted to the nose. If problems arise regarding pressure control, it is advisable to fit a
new Relief Valve.
3) Should any hydraulic fittings and bonded seals be removed it is advisable to refit using new
seals after examining the fitting to ensure that there is no damage.
4) The By-Pass spool (Item 1B) can be extracted by removing the lever/knob (Items 5 & 6) after
slackening the grub screw (Item 3) and then removing the Boss (Item 4) from the top of the
spool. The Circlip (Item 22) can then be removed from the other end. The spool should then
be removed by gently pushing from the Circlip end until the 'O' Ring is revealed, and after
removal of this ring the spool should be pushed right through the opposite way thus avoiding
seal damage.
Refitting the spool is the reverse of the above by fitting the bottom 'O' Ring and pushing the
spool through the block to reveal the second 'O' Ring groove. The second seal can then be
fitted and the spool pushed back to its correct position and secured by the Circlip and boss.
NOTE- To refit the valve block, carry out the reverse of the above instructions taking care to fit a new
gasket (Item 29) and before bolting the valve block to the tank ensure that the blanking plug (Items
28) is correctly fitted into the housing in the block and also ensure that the spigot locates into its
location hole in the clamping plate.

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3.5.4. - COOLER - Refer to Fig 3.4.
a) Remove the frame as described in 3.5.1. above.
b) Remove the cowl as described in 3.5.2. above.
c) Remove the two pipe connections at the cooler using two spanners (ie:- supporting the cooler
connection fitting against twisting and bending).
NOTE - It may prove advisable to remove the pipes completely before attempting to extract the cooler
from its housing. Remember that the cooler and pipes will be full of hydraulic oil.
d) Unscrew the 6 off screws (Item 5) and 2 off Screws (Item 13) holding the cooler (Item 1) and
Guard (Item 2) to the fan housing, and retain the Nuts (Item 3) and Washers (Item 4).
e) Gently pull the Cooler from its housing complete with Guard and separate.
NOTE - Refitting the cooler assy is the reverse of the above, however it should be noted that the
cooler is manufactured from soft materials and should therefore be treated carefully to avoid damage.
It is strongly recommended that new Shakeproof Washers (Item 14) are fitted on reassembly and that
the 2 off Set Screws (Item 13) are loctited into position using Nutlock or similar strength product.

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3.5.5.- PUMP - Refer to Fig 3.5
a) Drain hydraulic tank as described in 3.5.2.
b) Disconnect H.P. Feed pipe as described in 3.5.3.
c) Disconnect the suction hose (Item 21) at both swivel connections at the Tank (Item 22) and
the Pump (Item 13).
d) Remove and retain the 4 off Cap Screws (Item 14) securing the pump (Item 11) to the
Pump Conversion Plate (Item 26)
e) Withdraw the Pump away from the Pump Conversion Plate taking care to retain the nylon
insert between the coupling halves.
f) Where a pump replacement is required it is necessary to remove the drive coupling half from
the pump shaft by folding back the locking tab on the Tab Washer and removing the Nut. The
coupling half will usually require a puller for removal as it is prone to locking on its taper. The
port connectors (Items 9 & 12) must also be removed.
NOTE - Refitting the pump is the reverse of the above, however it is recommended that new Bonded
Seals (Item 10) are fitted, taking care to ensure that the port adaptors are not damaged.
3.5.6. - FAN - Refer to Fig 3.5.
a) Remove the pump as described in 3.5.5.
b) Remove the Valve Block as described in 3.5.3.
c) Remove 3 off Nuts (Item 16) and Washers (Item 17) and withdraw the Pump Plate (Item 18)
to reveal the Fan and Drive Coupling half.
d) Slacken the Grub Screw (Item 7) securing the Drive Coupling Half (Item 8) and slide off the
shaft.
e) Slacken off the 2 off Grub Screws securing the Fan (Item 6) to the Shaft Extension, and slide
off the Fan. Retain the Shaft Key.

19
3.5.7. - ENGINE - Refer to Fig 3.5.
a) Remove the Fan as described in 3.5.6..
b) Remove the 4 off bolts (Item 23) securing the engine to the Tank, remember to support the
weight of the Engine Spacer (Item 1).
c) Remove the 4 off Set Screws (Item 14 Fig 3.1) to release the Engine from the Chassis.
d) The Engine can now be lifted clear of the Tank/Chassis.
NOTE:- If an engine replacement is necessary the Shaft Extension fitted to the Engine shaft must be
taken off by removing the Retaining Bolt (Item 4). The Shaft Extension can then be slid off the engine
shaft once the Grub Screws (Item 2) have been unscrewed.
3.5.8. - POWER ON DEMAND SYSTEM - Refer to Fig 3.6.
NOTE - The P.O.D. Cylinder and cable assy are designed as a cartridge which can be disassembled
completely without disturbing any other part of the Power Pack.
a) Slacken the P.O.D. Retaining Nut (Item 8) and unscrew fully.
b) Pull down the Nut/Cable to extract the Spring (Item 5) and Piston (Item 3) for examination.
NOTE - To connect a new Cable the piston can be withdrawn sufficiently to reveal the Grub Screw
(Item 4) which clamps the cable to the piston allowing access without extracting the 'U' Ring (Item 2)
from the body.
c) The P.O.D. Body (Item 7) can be unscrewed from the Valve Block for examination if desired.
d) The Cable can only be removed from the Tank by removal of the Clamps (Item 12). These
clamps are plastic and cannot be removed without damage. Replace the clamps upon
reassembly.
NOTE - Reassembly is the reverse of the above procedure. However, care should be taken when
fitting the Piston Seal (Item 2) into the bore of the body (Item 7). Standard cable length allows for the
cable to be pushed fully home into the piston before clamping by the grub screw (Item 4).
When unit is fully reassembled adjuster (item 10) can be adjusted as follows:-
Adjustment
a) Start engine with cable slack and check flow and pressure as per section 3.4.
b) Off load the machine by operating the By-pass lever.
c) Adjust the cable tightness by using the adjuster (item 10) until the engine speed drops to
1800-2200 rpm.
d) lock off adjuster and check that engine reaches high speed when system pressure is raised
e) Repeat if settings are not as specified.

20
SECTION 4 - PARTS IDENTIFICATION LISTS.
4.1 SPARES HOLDING INFORMATION.
To reduce down time of the Hydraulic Power Unit it is recommended that the following parts are
available for immediate replacement.
ITEM PART NO. QTY
Pressure Gauge 00005/2 1 off
Gauge Seal 00006 10 off
Tank Lid Gasket 00858 1 off
Oil Cooler 01414 1 off
Valve Block Gasket 00803 1 off
QRCProbe 00545 2 off
QRCCarrier 00546 2 off
Drive Coupling 01453 1 off
Float Switch 00790 1 off
Filter Can 00178 1 off
Cable Assy 01014 1 off
POD Assy 00921 1 off
Cable Clamp 01031 2 off