Y15.30-0066-09
Starter Removal |
1 | Engine top side heat cover | 4 | Catalytic converter mounting clamp | |
2 | Engine RHS side heat cover | 5 | Exhaust pipe middle mounting clamps | |
3 | Exhaust pipe mounting clamp | 6 | Catalytic converter assembly |
Y15.30-0067-09
7 | Turbocharger heat shield | 10 | Starter motor solenoid connection | |
8 | Starter earth connection fitting | 11 | Catalytic converter supporting bracket | |
9 | Starter motor housing positive connection | 12 | Starter motor |
Y15.30-0068-09
Starter Disassembly |
13 | Eyelet assembly | 17 | Solenoid switch | |
14 | Relay ground connection cable | 18 | Pinion | |
15 | Relay assembly | 19 | Jump ring | |
16 | Starter terminal clamp |
Y15.30-0088-09
20 | Thrust collar | 24 | CE carrier mounting bolts | |
21 | Journal shaft pinion | 25 | CE Bracket | |
22 | Drive assembly spring | 26 | Armature assembly washer | |
23 | Brush gear assembly fixing screw |
Y15.30-0070-09
27 | Seal mounting screw | 30 | Yoke assembly seal | |
28 | Carbon brush | 31 | Armature assembly | |
29 | Brush gear | 32 | Armature assembly ball |
Y15.30-0071-09
33 | Armature assembly ball bearing | 36 | Planetary gear | |
34 | Yoke assembly | 37 | DE Packing | |
35 | Gear cover plate | 38 | Inter carrier assembly seal |
Y15.30-0072-09
39 | Output shaft assembly | 44 | Drive assembly | |
40 | Output shaft assembly with lever | 45 | ‘E’ clip | |
41 | Fixing bracket assembly | 46 | Output shaft | |
42 | Output shaft assembly lever | 47 | Inter carrier assembly | |
43 | Output shaft assembly | 48 | Inter carrier assembly washer |
Y15.30-0073-09
49 | Ball bearing of inter carrier | 53 | Needle bearing | |
50 | Pin | 54 | Rubber cover | |
51 | Bush | 55 | Fixing bracket bearing | |
52 | Lever | 56 | Fixing carrier seal |
Y15.30-0074-09
Starter Assembly |
49 | Ball bearing of inter carrier | 53 | Needle bearing | |
50 | Pin | 54 | Rubber cover | |
51 | Bush | 55 | Fixing bracket bearing | |
52 | Lever | 56 | Fixing carrier seal |
Y15.30-0075-09
39 | Output shaft assembly | 44 | Drive assembly | |
40 | Output shaft assembly with lever | 45 | ‘E’ clip remover | |
41 | Output shaft assembly with carrier | 46 | Output shaft | |
42 | Output shaft assembly lever | 47 | Inter carrier assembly | |
43 | Output shaft assembly | 48 | Inter carrier assembly washer |
Y15.30-0076-09
32 | Armature assembly ball | 36 | Planetary gear | |
34 | Yoke assembly | 37 | DE Packing | |
35 | Gear cover plate | 38 | Inter carrier assembly seal |
Y15.30-0077-09
26 | Armature assembly washer | 30 | Yoke assembly seal | |
27 | Seal mounting screw | 31 | Armature assembly | |
28 | Carbon brush | 33 | Armature assembly ball bearing | |
29 | Brush gear |
Y15.30-0078-09
17 | Solenoid switch | 22 | Drive assembly spring | |
19 | Jump ring | 23 | Brush gear assembly fixing screw | |
20 | Thrust collar | 24 | CE carrier mounting bolts | |
21 | Journal shaft pinion | 25 | CE Bracket |
Y15.30-0089-07
13 | Eyelet assembly | 15 | Relay assembly | |
14 | Relay ground connection cable | 16 | Starter terminal clamp |
Y15.30-0080-09
Starter Refitment |
7 | Turbocharger heat shield | 10 | Starter motor solenoid starter connection | |
8 | Starter earth connection | 11 | Catalytic converter supporting bracket | |
9 | Starter motor housing positive connection | 12 | Starter motor |
Y15.30-0081-09
1 | Engine top side heat cover | 4 | Catalytic converter mounting clamp | |
2 | Engine RHS side heat cover | 5 | Exhaust pipe middle mounting clamps | |
3 | Exhaust pipe mounting clamp | 6 | Catalytic converter assembly |
| Remove/install | ||
1 | Tilt the cab | Tilt cab to repair position, tilt back | |
2 | Remove the engine top side heat cover (1) | ||
3 | Remove engine RHS side heat cover (2) | ||
4 | Remove exhaust pipe mounting clamp (3) from turbocharger | ||
5 | Remove catalytic converter mounting clamp (4) | ||
6 | Remove exhaust pipe middle mounting clamps (5) | ||
7 | Remove catalytic converter assembly (6) from exhaust pipe | ||
8 | Remove the heat shield (7) from turbocharger | ||
9 | Remove the starter ground connection (8) from flywheel housing | By using 18 mm hexagonal socket and locking pawl. | |
Installation: By using 18 mm hexagonal socket and torque wrench. | |||
10 | Remove the positive connection fitting (9) from starter housing | By using 19 mm hexagonal socket and locking pawl. | |
Installation: By using 19 mm hexagonal socket and torque wrench. | |||
11 | Remove the starter connection fitting (10) from starter solenoid | ||
12 | Remove catalytic converter support arm (11) from starter | By using 18 mm hexagonal socket and locking pawl. | |
Installation: By using 18 mm hexagonal socket and torque wrench. | |||
13 | Remove starter (12) from flywheel housing | By using 18 mm hexagonal socket and locking pawl. | |
Installation: By using 18 mm hexagonal socket and torque wrench. | |||
Starter motor to flywheel housing | |||
| Disassemble/assemble | ||
14 | Remove both cables and eyelet assembly (13) top portion | By using 19 mm hexagonal socket and locking pawl. | |
15 | Remove relay ground connection cable (14) assembly | ||
16 | Remove relay assembly (15) | By using screwdriver. | |
17 | Remove starter terminal clamp (16) nut from the solenoid switch | By using 17 mm hexagonal socket and locking pawl. | |
18 | Remove the solenoid switch (17) from starter assembly | By using screw driver. | |
19 | Tap the pinion (18) | By using drift and hammer. | |
Gently tap the pinion top side and remove the jump ring. | |||
20 | Remove the jump ring (19) | By inserting a screwdriver in between shaft and ring and when the pinion is in forward condition by holding the engaging lever downwards using screwdriver. | |
21 | Remove the thrust collar (20) from the pinion assembly | ||
22 | Remove pinion (21) from journal shaft | ||
23 | Remove spring (22) from drive assembly | ||
24 | Remove brush gear assembly fixing screw (23) from CE carrier | By using screwdriver. | |
25 | Remove CE carrier mounting bolts (24) | ||
26 | Remove CE carrier (25) | By gently tapping with the mallet. | |
27 | Remove washer (26) from armature assembly | ||
28 | Remove seal mounting screw (27) from brush gear assembly | By using screwdriver. | |
29 | Release lock and remove carbon brush (28) | By using screwdriver. | |
30 | Remove brush gear (29) from armature assembly | ||
31 | Remove seal (30) from yoke assembly | ||
32 | Remove armature assembly (31) from fixing carrier assembly | ||
33 | Remove ball (32) from armature assembly | ||
34 | Remove ball bearing (33) from armature assembly | By using puller. | |
35 | Remove yoke assembly (34) | ||
36 | Remove gear cover plate (35) from inter carrier and bearing assembly | ||
37 | Remove planetary gear (36) | ||
38 | Remove DE packing (37) from inter carrier assembly | ||
39 | Remove seal (38) from inter carrier assembly | ||
40 | Remove output shaft assembly (39) along with lever (40) from fixing carrier assembly (41) | ||
41 | Remove lever (42) from output shaft assembly | ||
42 | Remove output shaft assembly (43) from drive assembly (44) | ||
43 | Remove ‘E’ retaining clip (45) from output shaft assembly | ||
44 | Remove output shaft (46) from inter carrier assembly (47) | ||
45 | Remove washer (48) from inter carrier assembly | ||
46 | Remove ball bearing (49) from inter carrier assembly | By using drift and hammer. | |
47 | Remove pin (50) and bush (51) from lever (52) | ||
48 | Remove needle bearing (53) from output shaft | ||
49 | Remove rubber cover (54) from solenoid | ||
50 | Remove fixing carrier bearing (55) | By using drift and hammer. | |
51 | Remove seal (56) from fixing carrier assembly | ||
52 | Assemble in the reverse order | ||
53 | Install in the reverse order |
Referenced documents
- ar6080y0010a Tilt cab to repair position, tilt back