Usage:
Remove And Install Air Starter
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Be sure the air supply to the air starter is turned off. |
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TYPICAL EXAMPLE
1. Remove tubes (1) from the starter drive assembly housing.
2. Disconnect starter air inlet line at union (2).
3. Fasten a hoist (not shown) to the air start motor. Remove three bolts (3) and remove the air starter. The weight of the air starter is 85 lb. (39 kg).
TYPICAL EXAMPLE
4. Install a new gasket between the air starter and the flywheel housing. Install the air starter with three bolts (3) and lockwashers.
5. Connect the starter air inlet line (2) to the air starter.
6. Connect tubes (1) to the starter drive assembly housing.
Disassemble Air Starter
start by:
a) remove air starter
NOTE: Make sure there is a complete set of new gaskets, vanes, seals and O-ring seals before the air starter is disassembled.
1. Make a mark to show the position of housing assembly (1) respective to cover (2) for assembly purposes.
2. Remove the bolts that hold the housing assembly in position and remove the housing assembly from the cover.
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Put drive housing (1) in an arbor press, piston end up. Apply force to drive assembly (4) to compress spring (5) before removing the retainer. Be sure spring (5) forces drive assembly (4) out of housing (1) while releasing the press. Failure to observe this procedure can result in personal injury. |
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3. Remove drive assembly (4), spring (5) and seat (3) from the housing assembly.
4. Remove plug (7), oiler and bushing (6) from housing (8).
5. Disassemble the drive assembly as follows:
a) Remove seal ring (9) from piston (10).
b) Remove retainer (13) from the piston with tool (A).
c) Slide the piston toward the gear end of clutch assembly (12).
d) Remove spacer (14) and two shift rings (11) from the clutch assembly.
NOTE: Do not clean the clutch assembly in kerosene or other solvent.
e) Remove piston (10) from clutch assembly (12).
6. Make a mark to show the position of cover (2) respective to the housing for assembly purposes. Remove the bolts that hold the cover in place.
7. Remove the cover with shaft assembly (16) and washer (17) from case assembly (15).
8. Remove the shaft assembly from the cover.
9. Remove seal (18) and O-ring seal (19) from the cover.
NOTE: Some air starters have a snap ring on top of seal (18) to hold the seal in place. Remove this snap ring before the seal is removed.
10. Remove gear (21) from shaft (20) with a press.
11. Remove key (22) and remove bearing (23) from the shaft with a press.
12. Make a mark to show the position of case assembly (15) respective to housing (24) for assembly purposes. Remove the bolts and nuts that hold case assembly (15) in position.
13. Remove the case assembly from housing (24).
14. Remove needle bearing (25) from the case assembly.
15. Remove the lockwire, bolts and gear retainer (26) from the rotor.
16. Install gear retainer (26) in an up side down position on the rotor and install the bolts that hold it in place. Do not tighten the bolts completely.
17. Install tooling (B) under gear (27) and remove the gear from the rotor.
18. Remove the bolts that hold cover assembly (28) on the opposite end of housing (24).
19. Remove the cover assembly with gasket (30) and rotor and cylinder assembly (29) from the housing.
20. Remove washer (31) from the plate bearing.
21. Remove lock (32) from nut (33) and remove the nut from the rotor with tool (C).
22. Remove lock (32), plate (35), cylinder (34), dowel (38) and spacer (37) from rotor (36).
23. Remove bearing (39) from plate (35).
24. Remove four retainers (40) from the cylinder.
25. Remove five vanes (41) from the rotor.
26. Remove plate (42) from the rotor and remove bearing (43) from the plate.
27. Remove spacer (44) from the rotor.
Assemble Air Starter
NOTE: Clean all parts thoroughly. Put 2S3230 Bearing Lubricant on all bearings and the drive assembly. Put a thin layer of SAE 10W oil on all other parts before assembly.
1. Install spacer (1) and plate (3) on the end of rotor (2) that has a taper.
2. Make sure the side of bearing (4) that has a shield, is in a down position. Install the bearing in the plate with tool (A) and a press.
3. Install five vanes (5) in the rotor.
4. Install four retainers (9) in cylinder (8).
5. Install dowel (10) in the plate and install the cylinder on the dowel and rotor.
NOTE: Make sure the dowel is installed in two holes (6) in either end of the cylinder. Two holes (7) in the cylinder must be in alignment with two left holes (11) in the plate. Two right holes (12) are not used for this model of air starter.
6. Install spacer (15) on the rotor.
7. Install plate (13) on the cylinder. Make sure hole (14) in the plate is in alignment with the dowel.
8. Make sure the side of bearing (16) that has a shield is in a down position. Install the bearing in the plate and install the lock on the rotor.
9. Install the nut with its large chamfer in a down position. Tighten the nut with tool (B) and bend the lock into one of the grooves of the nut to hold the nut in position.
10. Make a record of the four holes (20) and dowel hole (18) in housing (19). Dowel hole (17) is not used on this model of air starter.
11. Four retainers (9) in the cylinder must be in alignment with four holes (20) in the housing. Also, dowel (10) must be in alignment with hole (18) in the housing. Install rotor and cylinder assembly (21) in the housing.
12. Install washer (23) on the plate bearing.
13. Install gasket (24) on the plate and install cover assembly (22) on the housing. Install the bolts that hold the cover assembly in position. Turn the rotor as the bolts are tightened to make sure the rotor will turn freely.
14. Turn the housing over and install gear (26) on the rotor. Make sure key (27) is in alignment with notch (25) on the gear as shown.
15. Install retainer (28) and the two bolts that hold it in position.
16. Use this procedure to tighten the two bolts:
a) Remove the plug from the cover assembly.
b) Install a ratchet and extension in the end of the rotor as shown.
c) Tighten the bolts to standard torque and hit the retainer with a hammer. Tighten the bolts again to standard torque.
17. Put the identification marks of the needle bearing in an up position. Install the needle bearing in case assembly (30) with tooling (C). The top of the bearing must be even with surface (29).
18. Install the case assembly in its original position on housing (19) and install the bolts and nuts that hold the case assembly in position.
19. Install bearing (32) on shaft (31) with a press.
20. Install key (34) on the shaft.
21. Install gear (33) on the shaft with a press as shown. Make sure the key is in correct alignment with the groove in the gear.
22. Install washer (35) on the needle bearing of the case assembly.
23. Install shaft assembly (36) on the washer of the case assembly.
24. Use tool (D) and install seal (39) in cover (38) with the large metal surface in an up position. The large metal surface must not be above counterbore (37) in the cover. Put a thin layer of oil on the lip of seal (39).
NOTE: Some air starters have a snap ring to hold seal (39) in position. In this type of starter, the seal must be installed below the snap ring groove in the cover and the snap ring must be installed on top of the metal surface of the seal.
25. Install O-ring seal (40) on the cover.
26. Install the cover in its original position on the case assembly. Use a seal pick to put the lip of the seal in its correct position on the shaft. Install the bolts that hold the cover in position.
27. Assemble the drive assembly as follows:
a) Install piston (41) on clutch assembly (42) as shown.
b) Install two shift rings (44) in the groove of the clutch assembly.
c) Install spacer (43) on the shift rings.
d) Lift the piston and install retainer (45) in the groove of the piston with tool (E).
28. Install drive assembly (46) as shown on the shaft.
29. Install seal ring (49) on the piston.
30. Install spring (47) and seat (48) on the drive assembly.
NOTE: The counterbore of the seat must be in a down position.
31. Install the bushing in housing (50) with tool (D). Put the notch in the bushing in alignment with the hole in the housing.
32. Install oiler (51) in the housing and install the plug that holds the oiler in place. Do not tighten the plug at this time.
33. Install housing assembly (53) in its original position on cover (38).
34. Install the bolts that hold the housing assembly in position. Tighten the bolts evenly a small amount at a time to a torque of 100 lb.in. (11.3 N·m).
35. Tighten plug (52).
36. Use this procedure to see if the cylinder is installed correctly:
a) Install tooling (F) on the inlet side of the housing.
b) Put air pressure into the housing to cause the rotor to turn.
c) From the drive assembly end of the air starter, the shaft will turn in a clockwise direction.
NOTE: If the shaft turns in a counterclockwise direction, remove the cylinder and rotor assembly from the housing and turn the cylinder end for end on the rotor.
37. Use this procedure to make a check of the movement of the drive assembly:
a) Put air pressure into the housing assembly through hole (55) with tool (G).
b) The drive assembly will move to the engaged position and the exhaust air will come out through hole (54) in the housing assembly.
NOTE: If the drive assembly does not move, disassemble the housing and drive assemblies and make a check of the seals in these assemblies. Also, make sure the drive assembly has correct lubrication. Use 2S3230 Bearing Lubricant on the drive assembly.
end by:
a) install air starter