21549291 Volvo.Penta Bracket

1. Close the air pressure supply and drain the air pressure from the system.2. Disconnect hoses (1) from air lines group (4).3. Remove four bolts (2) that hold the elbow and air lines group on the air starter.4. Remove U-Bolt (3) and air lines group (4). 5. Disconnect hose (5) from air starter (6).6. Fasten a hoist to air starter (6). Remove three bolts (7) and remove the air starter from the flywheel housing. The weight of the air starter is 48 Kg (105 lb.). The following steps are for the installation of the air starter.7. Fasten a hoist to air starter (6), and put it and the gasket in position. Install three bolts (7) that hold the air starter to the flywheel housing.8. Connect hose (5) to the air starter.9. Position air lines group (4). Install U-Bolt (3) and four bolts that hold the air lines group to the air starter.10. Connect hoses (1) to the air lines group and open the air pressure supply to the system.Disassemble Air Starter
Start By:a. remove air starter 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. Make marks to show the position of motor housing (3), in relation to gear case (6), for assembly purposes. Remove bolts (4) to remove gear case (6) and drive housing (5) as a unit from motor housing (3). 3. Use tool (A) to remove ring (8) from drive gear (7). 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. Make marks to show the position of drive housing (5), in relation to gear case (6), for assembly purposes. Remove bolts (12) and remove 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). Use a press to make a compression of 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) from between the drive gear and piston and remove ring (15) from the piston. Remove the drive gear, the piston and drive shaft assembly as a unit from the drive housing. Remove piston return spring (16) from the drive housing. 9. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free and 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) and remove the piston from 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). Any time ring (32) is removed, a replacement must be made.15. Remove ring (32) and remove bearing (33) from drive shaft (17). 16. Use tool (C) to remove ring (35) and 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. Make marks to show 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) to remove rotor pinion (40) from rotor shaft. 21. Loosen bolt (43) and remove nut (42) from the rotor shaft.22. Remove bearing (44) from end plate (45). 23. Remove O-ring seal (46) and end plate (45) from the end of the rotor. 24. Remove vanes (47) from rotor (48). 25. Remove rotor (48) from motor housing (3). 26. Use a press to 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
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) and install the cylinder in housing (3). Make sure pin (55) is in alignment 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) on the rotor shaft. 5. Install bearing (44) over the rotor shaft and in the end plate. 6. Install nut (42) on the rotor shaft, with the shoulder toward the bearing. 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) in motor housing (3) with the pinion end of the rotor toward the cylinder alignment pin. Make sure pin (57) is in alignment with the hole in the end plate. 9. Install vanes (47) in the rotor. 10. Install end plate (50) on the rotor and make sure hole (58), in the end plate, is in alignment with pin (59). 11. Install washers (51) in the end plate.