Usage:
1. Close the air pressure supply and drain the air pressure from the system.
2. Disconnect hoses (1).
3. Remove four bolts (2).
4. Remove U-Bolt (3) and air lines group (4).
5. Disconnect host (5).
6. Fasten a hoist to air starter (6). Remove three bolts (7) and the air starter and the gasket. The weight of the air starter is 48 kg (105 lb).
NOTE: Install in reverse order.
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) and bracket (2) from motor housing (3).
2. Mark the position of motor housing (3) in relation to gear case (6) for assembly purposes. Remove bolts (4) and remove gear case (6) and drive housing (5) as a unit.
3. Using tool (A), remove ring (8) from drive gear (7).
NOTE: Bolt (9) has left hand threads.
4. Remove bolt (9) and washer (10) to remove drive pinion (11), a sleeve and a spring from the end of the drive shaft.
5. Mark the position of drive housing (5) in relation to gear case (6) for assembly purposes. Remove bolts (12) and drive housing (5) from gear case (6).
6. Remove O-ring seal (13) from drive housing (5).
 |
The drive shaft assembly, the piston and drive gear are under a spring force. |
 |
7. Install tooling (B) between drive gear (7) and piston (14). Using a press, compress the piston return spring, and remove the ring that holds the drive shaft assembly and piston in the drive housing.
8. Slowly, release the press to remove the force of piston return spring (16). Remove tooling (B). Remove ring (15). Remove the drive gear, the piston and drive shaft assembly as a unit from the drive housing. Remove piston return spring (16).
9. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free. Remove drive shaft assembly (17) and piston (14) as a unit from drive gear (7).
10. Remove bulkhead (18) from piston (14).
11. Remove O-ring seals (19) from bulkhead (18).
12. Remove ring (20) from piston (14). Remove the piston from the drive shaft assembly (17).
13. Remove O-ring seal (22) and seal (21) from piston (14).
14. Remove ring (31), cup (30), spring (29), driven clutch jaw (28), driving clutch jaw (27), bearing (26), washer (25), lockwasher (24) and bolt (23) from drive shaft assembly (17).
NOTE: Every time ring (32) is removed, a replacement is required.
15. Remove ring (32) and remove bearing (33) from drive shaft (17).
16. Using tool (C), remove ring (35). Remove bearing (34) from gear case (6).
17. Remove seat (36) and bearing (37) from drive housing (5).
18. Remove seal (38) from drive housing (5).
19. Mark the position of cover assembly (39) in relation to motor housing (3) for assembly purposes. Remove cover assembly (39) and an O-ring seal from motor assembly (3).
20. Remove bolt (41) and rotor pinion (40) from the rotor shaft.
21. Loosen bolt (43) and remove nut (42).
22. Remove bearing (44) from end plate (45).
23. Remove O-ring seal (46) and end plate (45).
24. Remove vanes (47) from rotor (48).
25. Remove rotor (48) from motor housing (3).
26. Using a press, remove bearing (49) and end plates (50) as a unit from rotor (48).
27. Remove bearing (49) from end plate (50).
28. Remove washers (51) from end plate (50).
29. Remove O-ring seals (52) from cylinder (53).
30. Remove cylinder (53) from motor housing (3). Remove the remaining two 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 (54) on cylinder (53). Install the cylinder in housing (3) with pin (55) aligned with opening (slot) (56) in housing (3).
2. Install O-ring seals (52) on cylinder (53).
3. Install end plate (45) on rotor (48).
4. Install O-ring seal (46).
5. Install bearing (44) over the rotor shaft and in the end plate.
6. Install nut (42) with the shoulder toward the bearing on the rotor shaft.
7. Tighten the nut until there is .02 mm to .07 mm (.001 in to .003 in) clearance between the end plate and the rotor. Use a feeler gauge to check the clearance. Tighten bolt (43) and check the clearance again.
8. Install rotor (48) with the pinion end of the rotor toward the cylinder alignment pin in motor housing (3). Pin (57) must be aligned with the hole in the end plate.
9. Install vanes (47).
10. Install end plate (50), with hole (58) aligned with pin (59) on the rotor.
11. Install washers (51).
12. Position bearing (49) on the end plate.
13. Using tooling (E) and a press, finish installing bearing (49) on the rotor shaft and in the end plate.
14. Install rotor pinion (40) and the bolt. Tighten the bolt to a torque of 120 N·m (90 lb ft).
15. Install O-ring seal (60) around the rotor bearing. Install cover assembly (39) on motor assembly (3).
16. Install bearing (33) and ring (32) on drive shaft (17).
17. Using a press and tool (D), install the ring on the drive shaft.
18. Install bolt (23), lockwasher (24), washer (25), bearing (26), driving clutch jaw (27), driven clutch jaw (28), spring (29) and cup (30) in drive shaft assembly (17). Install ring (31).
19. Using tooling (E), install the seal in piston (14). Make sure the lip of the seal is toward the outside of the piston.
20. Install O-ring seal (22).
21. Install piston (14) on drive shaft assembly (17) and install ring (20).
22. Install O-ring seals (19) on bulkhead (18).
23. Install bulkhead (18) on piston (14).
24. Install drive gear (7) on drive shaft assembly (17). Use a 5/16" Allen wrench to install the drive gear bolt. Tighten the bolt to a torque of 77 N·m (57 lb ft).
25. Using tooling (E), install the seal in drive housing (5). Make sure the lip of the seal is toward the outside of the housing as shown.
26. Install bearing (37).
27. Install seat (36).
28. Install pinion return spring (16).
29. Install the drive gear, the piston and drive shaft assembly, as a unit, on the piston return spring.
30. Install ring (15) over the piston and install tooling (B) between the drive gear and piston. Using a press, compress the piston return spring and install ring (15) in the groove of the drive housing. Release the press and remove tooling (B).
31. Install bearing (34) in gear case (6). Using tool (C), install the ring that holds the bearing in the gear case.
32. Install drive housing (5) in gear case (6). Make sure the shaft on the end of the drive gear is correctly engaged with the bearing in the gear case. Install the bolts and tighten them to a torque of 38 N·m (28 lb ft).
33. Using tool (A), install ring (8).
NOTE: Bolt (9) has left hand threads.
34. Install spring (62), sleeve (61), drive pinion (11), bolt (9) and the washer on the end of the drive shaft. Tighten bolt (9) to a torque of 108 N·m (80 lb ft).
35. As a unit, install gear case (6) and drive housing (5) on motor housing (3). Install bolts (4). Evenly tighten to a torque of 81 N·m (60 lb ft).
36. Install the gasket, elbow (1) and bracket (2) on motor housing (3).
37. To check the operation of the air starter, use the following procedure.
a. Turn drive pinion (11) by hand in the direction of the starter rotation. The drive clutch must operate with a smooth (clicking) action.
b. Turn drive pinion (11) 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 drive housing. Drive pinion (11) 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 (11) to the mounting face of the drive housing. The dimension must be 73 ± 2.0 mm (2.874 ± .08 in). Remove the air pressure from the inlet opening and measure the 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