Usage:
1. Release the air pressure in the system.
 |
Make sure all of the air pressure in the system is released before disconnecting any air lines. |
 |
2. Disconnect the hose assemblies from fittings (3) and (4).
3. Fasten a hoist to air starter (1). Remove three bolts (2) and the air starter from the flywheel housing. The weight of the air starter is 54 kg (120 lb).
4. Remove the gasket from the air starter.
NOTE: The following steps are for installation of the air starter.
5. Put the gasket and air starter (1) in position on the flywheel housing, and install bolts (2).
6. Connect the hose assemblies to fittings (3) and (4).
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. Remove elbow (1) from cover assembly (2).
2. Remove silencer group (4) from motor housings (3).
3. Put identification marks to show the position of motor housing (3) in relation to gear case (7) for assembly purposes. Remove bolts (5) to remove gear case (7) and drive housing (6) as a unit from motor housing (3).
4. Use tool (A) to remove ring (9) from drive gear (8).
NOTE: This air starter is a right hand model, and bolt (10) has left hand threads. Right hand model is R.H. pinion rotation, as seen from the drive end.
5. Remove bolt (10) and washer (11) to remove drive pinion (12), a sleeve and spring from the end of the drive shaft.
6. Make alignment marks to show the position of drive housing (6) in relation to gear case (7) for assembly purposes. Remove bolts (13), and remove drive housing (6) from gear case (7).
7. Remove O-ring seal (14) from drive housing (6).
|
Piston (15) holds a spring under compression. To prevent personal injury, carefully remove the ring that holds the piston in place and release the tension on the spring slowly. |
|
8. Install tooling (B) between drive gear assembly (8) and piston (15). Use a press to compress the piston return spring, and remove the ring that holds the drive shaft assembly and piston in the drive housing.
9. Slowly release the press to remove the force of piston return spring (17). Remove tooling (B) from between the drive gear and piston, and remove ring (16) from the piston. Remove the drive gear, the piston and drive shaft assembly as a unit from the drive housing. Remove piston return spring (17) from the drive housing.
10. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free, and remove drive shaft assembly (18) and piston (15) as a unit from drive gear assembly (8).
11. Remove bulkhead (19) from piston (15).
12. Remove O-ring seals (20) from bulkhead (19).
13. Remove ring (21) from piston (15), and remove the piston from drive shaft assembly (18).
NOTE: The air starters used on the "B" model trucks will not have bumper (23.
14. Remove O-ring seal (24), bumper (23) and seal (22) from piston (15).
15. Remove ring (33), cup (32), spring (31), driven clutch jaw (30), driving clutch jaw (29), bearing (28), washer (27), lockwasher (26) and bolt (25) from drive shaft assembly (18).
NOTE: Any time ring (34) is removed, a replacement must be made.
16. Remove ring (34) to remove bearing (35) from drive shaft assembly (18).
17. Use tool (C) to remove ring (37), and remove bearing (36) from gear case (7).
NOTE: The air starters used on the "B" model trucks will not have bumper (38) and back-up ring (39).
18. Remove bumper (38) from drive housing (6).
19. Remove back-up ring (39) from drive housing (6).
20. Remove seat (40) and bearing (41) from drive housing (6).
21. Remove seal (42) from drive housing (6).
22. Make alignment marks to show the position of cover assembly (2) in relation to motor housing (3) for assembly purposes. Remove cover assembly (2) and an O-ring seal from motor housing (3).
23. Remove bolt (44) to remove rotor pinion (43) from the rotor shaft.
24. Loosen setscrew (46), and remove nut (45) from the rotor shaft.
25. Remove bearing (47) from end plate (48).
26. Remove O-ring seal (49) and end plate (48) from the end of the rotor.
27. Remove vanes (50) from rotor (51).
28. Remove rotor (51) from motor housing (3).
29. Use a press to remove bearing (52) and end plates (53) from rotor (51).
30. Remove bearing (52) from end plate (53).
31. Remove washers (54) from end plate (53).
32. Remove O-ring seals (55) from cylinder (56).
33. Remove cylinder (56) from motor housing (3). Remove the remainder of the O-ring seals from the cylinder.
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 O-ring seals (1) on cylinder (2), and install the cylinder in housing (3). Make sure pin (5) is in alignment with opening (slot) (4) in housing (3).
2. Install O-ring seals (6) on cylinder (2).
3. Install end plate (7) on rotor (8).
4. Install O-ring seal (9) on the rotor shaft.
5. Install bearing (10) over the rotor shaft and in the end plate.
6. Install nut (11) on the rotor shaft with the shoulder toward the bearing.
7. Tighten the nut until there is .03 mm to .08 mm (.001 in to .003 in) clearance between the end plate and the rotor. Use a feeler gauge to check the clearance. Tighten bolt (12), and check the clearance again.
8. Install rotor (8) in motor housing (3) with the pinion end of the rotor toward the cylinder alignment pin. Make sure pin (13) is in alignment with the hole in the end plate.
9. Install vanes (14) in the rotor.
10. Install end plate (15) on the rotor, and make sure hole (16) in the end plate is in alignment with pin (17).
11. Install washers (18) in the end plate.
12. Put bearing (19) in position on the end plate.
13. Use tooling (B) and a press to install bearing (19) on the rotor shaft and in the end plate.
14. Install rotor pinion (20) and the bolt that hold it to the rotor shaft. Tighten the bolt to a torque of 120 N·m (90 lb ft).
15. Install O-ring seal (22) around the rotor bearing, and put cover assembly (21) in position on the motor housing.
16. Put bearing (25) and ring (23) in position on drive shaft (24).
17. Use a press and tool (A) to install the ring on the drive shaft.
18. Put bolt (30), lockwasher (31), washer (32), bearing (33), driving clutch jaw (34), driven clutch jaw (26), spring (27) and cup (28) in position in drive shaft assembly (24). Install ring (29) in the drive shaft assembly.
19. Use tooling (B) to install the seal in position (35). Make sure the lip of the seal is toward the outside of the piston as shown.
NOTE: The air starters used on the "B" model trucks will not have bumper (36).
20. Install O-ring seal (37) and bumper (36) on piston (35).
21. Install piston (35) on drive shaft assembly (24), and install ring (38) that holds the piston to the shaft assembly.
22. Install O-ring seals (39) on bulkhead (40).
23. Install bulkhead (40) on piston (35).
24. Install drive gear assembly (41) on drive shaft (24), and use a 5/16" Allen wrench to install the drive gear bolt that holds the drive gear to the drive shaft. Tighten the bolt to a torque of 77 N·m (57 lb ft).
25. Use tooling (B) to install the seal in drive housing (42). Make sure the lip of the seal is installed as shown.
26. Install bearing (43) in the drive housing.
27. Install seat (44) in the drive housing.
NOTE: The air starters used on the "B" model trucks will not have bumper (46) and back-up ring (45).
28. Install back-up ring (45) and bumper (46) in the drive housing.
29. Install piston return spring (47) in the drive housing.
30. Put the drive gear, the piston and drive shaft assembly as a unit in position on the piston return spring.
31. Put ring (48) in position over the piston, and install tooling (C) between the drive gear and piston. Use a press to compress the piston return spring, and install ring (48) in the groove of the drive housing. Release the press, and remove tooling (C).
32. Install bearing (49) in gear case (50), and use tool (D) to install the ring that holds the bearing in the gear case.
33. Install drive housing (42) in gear case (50). Make sure the shaft on the end of the drive gear is correctly engaged with the bearing in the gear case. Install the bolts that hold the drive housing to the gear case. Tighten the bolts to a torque of 36 N·m (28 lb ft).
34. Use tool (E) to install ring (51) on the end of the drive gear shaft.
NOTE: This is a right hand rotation starter, and bolt (52) has left hand threads.
35. Install spring (55), sleeve (54), drive pinion (53), bolt (52) and the washer on the end of the drive shaft. Tighten bolt (52) to a torque of 108 N·m (80 lb ft).
36. Install gear case (50) and drive housing (42) as a unit on motor housing (3). Install bolts (56), and tighten each bolt a little at a time to a torque of 80 N·m (60 lb ft).
37. Install silencer group (58) and a gasket on the motor housing.
38. Install elbow (57) and a gasket on the cover assembly.
39. To check the operation of the air starter, use the following procedure:
a. Turn drive pinion (53) by hand in the direction of the starter rotation. The drive clutch must operate with a smooth (clicking) action.
b. Turn drive pinion (53) in the opposite direction of the starter rotation. The drive pinion must turn by hand.
c. Put 345 kPa (50 psi) of air pressure in the inlet opening of the drive housing. Drive pinion (53) must move away from the drive housing, and air must come out of the outlet opening of the drive housing.
d. Put a plug in the outlet opening of the drive housing, and put 1034 kPa (150 psi) of air pressure in the inlet opening of the drive housing. Make sure there are no air leaks, and measure the dimension from the face of drive pinion (53) to the mounting face of the drive housing. The dimension must be 73.00 ± 2.0 mm (2.874 ± .08 in). Remove the air pressure from the inlet opening, and measure the same dimension again. The dimension must be 44.5 ± 2.0 mm (1.75 ± .08 in).
e. Put 620 kPa (90 psi) of air pressure in the inlet opening of the motor housing. The motor must run smoothly.
End By:
a. install air starter