Installation and Maintenance Information
Contents
1. lubrication 2 lubrication Ingersoll RandNo HDL2 10 TPB978 EN 4 HDL2 10W 5815 55825 5582. SS815 55825 55850 1 OUT 1 4 4 1 4 2 3 8 3 No SMB 618 6 No TA STR 100 7 No 150BMP 1064 W
3. 5 T 15 1 172 24 15 2
4. e x SR IAS Loctite Corporation 10W 1 3 A MA HDL2 5 psi eg FSR 1 30 58 16 E 1 4
5. Ingersoll Rand No HDL2 10 PB978 EN 4 HDL2 7B 10W Ingersoll Rand No NL 24 8 10 BEO m SS815 SS825 55850 1 2
6. 4 4 60 ft lb 81 4 Nm 1 2 ee ER 3
7. 150BMP 1054 JIC37 7 474 1 4 NPT NC37 74 7 1 1 2 NPT SMB618 1 1 2 P bd SRV 150 1 1 2 NTZ 1 1 2 UL Ke 15 Psi L 4 and M 4 N 977 OUT 37 pr Mor Wu NPT NPT J TPA844 2 03531480_ed13 4
8. BEA 4 3 8 5 HDL2 4 ft 12m Ingersoll Rand
9. TPA842 2 14 03531480_ed13 p SMB 618 HERAA 4 HE di 3 x 1 4 NPT i 37 1 4 NPT L E i B 3 1 2 NPT 14 aa posene gt 1 1 2 ERMER SRV150 SUA BALL E al Fe NU cimi 1 4 N PT 1 1 2 REA 150BMP 1054 1 1 2 NL 24 8 4 SRE id vum tg SRV150 E TPA843 2
10. HERMES EUGENE TPA847 2 SS815 SS825 SS850 SS815 G B 03 R 31 O 2 6 SS825 G 03 R 31 0 2 6 SS850 G D 09 R 5 0 2 E LL BERGE E El TPD1495 16 03531480 ed13 45558624 irools com
11. Z gt sp youl RM wu KK 4 56 B Ver SEJER C Haste d ngo DEE PER C DL el FAYE oco VIRKE DRL SSE BE TALA Ie ECC BY NO Bg EEE BEE WRG ch EG CS EE Se ero TE B2B SE BERGA Cet tg SEGA EH 3 HERRAT Meee BOGAN Rt 90 9910 FAME MG sd cin BY M qm EX PM pb MEER 570 IE Y 0 8 5 SI8SS la 9 1 OIL 06 OF 006 OF Bis BSH X agog SED SEL LAY 7 rz EN 091 9 i TE PULS L 0LW LZl 0 HB et LEN 8l t I CK Sat LAN 8L P L 59 98 1 i OZZL 507 8 ERE 4 XE TPA1325 1 03531480_ed13 12 55850 ww Xx 6 95 B vst 8 ERE bl E el TE EKM BEE BER EE GH el EC BY OK i EE Eo DOYS ACBIGH ch ME Se BE E Set EG SE EAS GH BENT ES B HERRAT MM EN DIETAS HPAN LEGTE TARAL HAHHA FAE RARER HA HY BEZ mele 35 T EET e sex i Rauset 370 ls 60 8 95 09855
12. IR SMB 441 SS660 A674 SM450 A735 TPC444 4 55815 SMB 618 4 15 Psi Pad UE 38 JIC 37 1 4 NPT JIC379 1 4 NPT JIC 37 1 1 2 NPT N x iem NE SRV150 3 1 1 2 xam 1 1 2 1 4 NPT NL 24 8 YY e d m 8 5 2 208 888 TE PEDER
13. 3 2 8 Q8 28 ft Ib 38 Nm 3
14. Loctite Corporation 03531480_ed13 Ingersoll Rand No NL 24 8 10 10W 1 1 3 HDL2 5 psi 6 uem
15. 4 RPE JIC 37 174 NPT 3 1 1 2 NPT a IC 4 SN IN OUT JIC 37 SRV150 1 1 2 3 1 4 1 1 2 14 NPT TY NL 24 8 B 2 4 D at lo M
16. SRV150 1 1 2 FRR BE ASE RF S5660 A674 ___ SM450 A375 TPA847 2 55815 SS825 SS850 SS815 G B 03 R 31 0 2 G 55825 G 03 R 31 o 2 G 185 LAY TT C SS850 G D 09 R 51 O 2 E 8155 Bn T
17. 1 1 2 SRV 150 E 23 gcn mh 7 OUT JIC 37 JIC 3727 274 114 NRE JIC37 14 Np SMB 618 1 1 2 1 4 NPT 4 zl JIC 3 j 9 1 242777 NPT m NL 24 8 4 k A _ 4
18. 5 1 4 4 OUT 6 No SS660 A674 No SM450 A735 7 JN 4 M10 150 18 EN 3 TPB978 HDL2 19
19. SRV150 IN A SRV150 4 1 1 2 EN 6 TPC444 4 SRV150 5 ud 2 100 ft lb 136 Nm 4 DEL IN 1 4 4
20. 1 HDL2 HDL2 KE Eu 1 5 Teflon Ag 2 HDL2 MR 3 8 1 1 4 4 E 4 SAE10 10W 03531480_ed13 55815 55825 ipu ww OE 5 1 56 5 gy BB BIER 2 TRENES 6 CP YSEREEI GC USER El Lait 020 SY UR LE NEON S X240 FAB FABER IC NEPPE FI MEL BREV Y RB ALU GREE HON
21. IN 4 3 8 5 HDL2 4 1 2 3 840228 8 Ingersoll Rand 10 82 100 HEF AE 136 4 4 HEER MINE IN TPB978 HDL2 Pa HDL2 HDL2 BER 3 8
22. SHOR Boba Hang AR DEAE 3 2 Eo MRS RE HEL 8 ry 28 me ida m 28 38 H 3 SM LER ABERDEEN 4 Sr 0 60 81 4 FX
23. 3 efor FU NF E FREDEN BUE ES D HER 15 1 1 2 24 i z Su 15 2 6 SER Ingersoll Rand No SMB 441 Sealant No 2 Permatex Loctite Pipe Sealant
24. Ingersoll Rand No SMB 441 No 2 Permatex Loctite 1 30 58 EU eee ard Ae BED 1 4 4
25. TPA842 2 22 03531480_ed13 C 4 SMB 618 Ns I IN zR P 3 1 4 B NPT J 4 Ag r g JIC 3 1 1 2 NPT SRV150 1 1 2 mum 1 1 2 NL 24 8 4 RA OUT zR F 37 1 4 JIC 377 VA NPT 1 VIET BASATA WERT TPA843 2 1 1 2 N PT
26. 1 1 2 HER No SMB 618 No TA STR 100 s No 150BMP 1064 R 1 4 4 GERDA fe 24 16 No 55660 A674 No SM450 A735 e 17 M10 1 18 PB978 EN 3 19 50 RA HDL2
27. dne 4 SS825 SS850 55815 1 1 2 24 8 1 OUT 1 4 4 14 2 3 8 3
28. HDL2 3 8 HDL2 U HDL2 1 4 4 1 4 03531480_ed13 15 B ar 2 HDL2 50 T 36 20 3 40 8 Teflon 4 SAE 10 10W 8 8 55815 55825
29. HERA 15 Psi us REMER LERNE 11 2 FEAA 1 4 NPT SRV150 1 1 2 Ness JIC 37 1 1 2 N PT 1 1 2 ili SMB618 1 4 NPT TPA844 2 03531480_ed13 te P E n A 1 1 2 FANA 4 SRV 150 REA 4 37 HO dd JIC 37 4 1 4 NPT J 15 4 T 7 acses
30. 10 50 T du PR 03531480_ed13 HDL2 2 IB HDL2 TPB978 HDL2 3 HDL2 1 8 NPTF 1 HDL2 1 4 3 8 4
31. NPI 1 1 2 NS 1 1 2 NPT AE gt 1 GO gt T 4 UN 838882 e 178 27 PTF SRV 150 1 1 2 i 1 1 2 IR SMB 441 y aE SS660 A674 SM450 A735 TPC444 4 SS815 SMB 618 15 Psi 4
32. JIC 37 Adapter 1 1 2 Relay 1 4 N PT Valve SRV 150 Lubricator 1 1 2 Pipe NE 8 Y JIC 37 Adapter A E L Air Pressun Gage 1 1 2 NPT To prune Starter Control Valve PP SMB618 1 1 2 Hose Relief Valve set at 15 Psi above regulator setting For gas operation the relief valve outlet must be connected into a safe place High Pressure Supply SRV 150 4 Hose IN Port JIC 37 Adapter 1 4 N PT gt In OUT Port JIC 37 Adapter 1 4 N PT 4 Hose 1 1 2 Relay Valve Pressure regulator maximum setting not to exceed pressure rating shown on starter nameplate High pressure system with engine prelube use when supply pressure is over rating of starter For natural gas operation starter main exhaust must be piped away To pipe the drive housing vent remove the drive housing plug and replace it with a suitable tubing line the tubing must vent at a safe location and must not be interconnected with any other exhaust lines which might introduce a back pressure on the drive housing vent Dwg TPA844 2 03531480 ed13 Typical Multiple Starter Installation 4 Hose 4 Hose Starter Control Valve 1 1 4 NPT SMI 618 4 Hose pee Rela
33. JIC 37e HET 1 1 4 NPT VA NPT 83 SMB 618 1 1 2 PT 4 SHE mu CL 1 1 1 2 NPT NL 24 8 1 1 2 FAA SRV150 Gade lis 55660 A674 SM450 A375 1 1 2 JIC 3 1 1 4 NPT 1 1 2 1 4 NPT JIC 37 d JIC 37 1 4 NPT JIC 37 4 o 1 2 N PT NL 24 8 Bled Babe 522229 EFAA 290159 POS 2 oa 43429 5566 0 674 RS 212 SM450 A375 5 3 1 2 JIC 37 JIC 37 JIC 37 gie 1 1 EE VA NPT 11 2 120 150 Psig L d JIC 37 1 1 2 NPPT D quu e Re FRE DUI 58 150 re ve ee
34. the drive housing vent MODEL CODING FOR 55815 55825 AND 55850 STARTERS MODEL CODING SS815 G B 03 R 31 0 2 G 55825 6 03 R 31 0 2 G Size Starter Drive Housing Type Starter Exhaust Gearing Orientation Code Drive Housing Inlet Rotation Type Pinion Drive MODEL CODING SS850 G D 09 R 51 0 2 E Size Starter Drive Housing Type Starter Exhaust Gearing Orientation Code Drive Housing Inlet Rotation Type Pinion Drive Dwg TPD1495 03531480 ed13 For natural gas operation starter main exhaust must be piped away To pipe the drive housing vent Tine vent at a safe location and must not be interconnected with any other exhaust lines ght introduce a back pressure on 45558624 ingersollrandproducts com
35. 88 591 E S6lv 10104 ul aloH 5ulJed BAUG bs B E 01 55932 104 6nld adig 8 0 Dwg TPA1325 1 03531480 ed13 Mounting Dimensions for Series 55850 Starters youl suoisuauuig WU leng 541 95 64 5 1ubiew savers Z 8 098 Bundwany a10jeg suon gt nusu Y Dead aseald 9 payi2ads asIWuau1O ssalur peddius aq Ilim 3 0 UWOUS uonelueauO plepuels S 370416 03 34 31150ddo aloH Bununow Od UO paseg si 3po uonejuauQ 6ulsnoH AUG Pinja uoissitusue1 ad 0 pasodx3 SI JaJB1S I4 aym suoneoi ddy 104 DaAO ddV jou ae sjapow eseu BuisnoH aAug 29130 apis 99 34 uo 5404 03005 Jo 195 58 55 UMOG Dalulod 1sneuxg Jo uoi 8 uoluld 91 uoneyog PlU BuisnoH aAug apo uohe1uauO 6uueaD jsneux3 491 85 91 1 6ulsnoH 3AUG 1 33 azis 370 15 Y 608 5 06855 003 1300N cc LCc 91 068v 069 v BulsnoH aug ijsneux3 wu suondo 0881 9 0 6 HEET y dl aul6u3 34 uo pallelsul eq PINOYS SJJJB1S ev 5910 O SLE uoddns ead 104 se ejd z 9990 9 091 pss von P ULS OLW pueH 146 eA oraz isneuxg 3 48 39 ONIY 998 PU 1 8 1 uonejoy
36. 1 2 ERU RI ee EFRZMESE EFRA 3 03531480_ed13 PS SRV150 IN 4 5 6 7 8 4 9 10 11 12 AF AP o 13 14 DEL 15 OUT MA 4 T HDL2 4187 1 8 NPTF Sn MA 1 1 2 SRV150 TPC444 4 EN 6 SUMP GE BADE T
37. 23 to the face of the mounting flange It should be 1 25 32 45 0 4 2 0 mm for Models SS815 55825 and 7 3 32 180 2 0 mm for Model 55850 4 Motor Vane Action Apply 90 psig 6 2 bar 620 kPa pressure using a 3 8 9 mm supply line to the inlet of the motor Starter should run smoothly 5 Motor Seals Plug the exhaust and apply 20 psig 6 1 4 bar 138 kPa pressure to the inlet of the motor Immerse the Starter for 30 seconds in a nonflammable solvent If the Starter is properly sealed no bubbles will appear 03531480 ed13 Troubleshooting Guide Trouble Probable Cause Solution Motor will not run No air supply Check for blockage or damage to air supply lines or tank Damaged Motor Assembly Inspect Motor Assembly and power train and repair or replace if necessary Foreign material in Motor and or piping Remove Motor Assembly and or piping and remove blockage Blocked exhaust system Remove Housing Exhaust Cover and check for blockage Defective Control Valve or Relay Valve Replace Control Valve or Relay Valve Loss of Power Low air pressure to Starter Check air supply Restricted air supply line Check for blockage or damage to air lines Relay Valve malfunctioning Clean or replace lines or Relay Valve Lube Relay Valve Exhaust flow restricted Check for blocked or damaged piping Clean or replace piping Check for dirt or foreign material and
38. JIC 37 Adapter 1 1 2 Pipe Lubricator NL 24 8 OUT Port JIC 3 IN Port JIC 37 Adapter 1 4 NR Adapter 1 4 NT 1 1 2 Hose JIC 370 Adapter 1 1 2 NPT 1 1 2 Pipe Valve SRV150 4 Hose Exhaust piped away for gas 4Hose or use muffer 5566 or deflector SM450 A375 itm A d IN Port JIC 370 Adapter 1 1 2 Pipe Adapter 1 4 NPT 1 1 2 Hose Pipe Size JIC 379 Adapter 1 1 2 NPT Lubricator See Chart 244 1 1 2 Relay Valve SRV150 114 Hose No of Starters Min Pipe Size Exhaust piped away for gas or 2 4 Hose use muffler SS660 A674 or 3 1 A deflector SM450 A375 4 3 5 3 1 2 m Adapter OUT Port 37 og IN Port 370 Adapter 1 4 NPT Supply must be adequate to maintain 120 150 Psi at the Starters with the Running Starters L Valve SRV1 Dwg TPA847 2 How to Order a Starter 1 2 Pipe Lubricator 1 1 2 Reay NL 24 8 Adapter 1 4 N PT 1 1 2 Hose J JIC 37 Adapter 1 1 2 N PT Exhaust piped away for gas or use muffler SS660 A674 or deflector SM450 A375 remove the drive housini it with a suitable tubing which mi
39. arbor press 12 Remove the Bulkhead 35 from the Piston 13 Remove the Outer Bulkhead O Ring 36 and the Inner Bulkhead O Ring 37 14 Slide the Drive Shaft 53 from the Drive Housing 15 Pull the Piston Return Spring 56 off the Drive Shaft NOTICE Do not remove the Front Drive Shaft Bearing 32 orthe Drive Housing Seal 33 unless replacement is necessary and new parts are available The Bearing and or the Seal will always be damaged when removed from the Drive Housing 16 Remove the Piston O Ring 50 from the Piston NOTICE The following operation will damage the Piston Seal 51 Therefore always have a replacement Seal on hand 17 Insert a large screwdriver blade through the Piston Seal so that it rests on top of the Clutch Spring Cup Pry the Seal out of the Piston 18 Press the Clutch Spring Cup 40 down and remove the Clutch Spring Cup Retainer 39 19 Remove the Clutch spring Cup and Clutch Spring 41 20 Remove the two Clutch Jaws 42 21 Remove the Front Drive Gear Bearing 44 Drive Gear Cup 45 Drive Gear Lock Washer 46 Drive Gear Screw O Ring 27 and Drive Gear Screw 26 22 Using a screwdriver remove the Large Drive Shaft Bearing Retainer 47 23 Press the Rear Drive Shaft Bearing and Drive shaft 53 out of the Piston If the Rear Drive Shaft Bearing needs to be replaced proceed as follows a Using a small chisel cut and remove the small drive shaft bearing retainer on the D
40. 4 and Lock Washers 4A alternately tightening each a little at a time to a final torque of 60 ft Ib 81 4 Nm 24 Install two of the Housing Cover Plugs 3 into the Motor Housing Cover inlet boss and tighten securely Drive Housing 1 Press the Rear Drive Short Bearing 54 onto the Drive Shaft 2 Slide the small bearing retainer convex side first onto the Drive Shaft Press it into position in accordance with the instructions packaged with the new Retainer 3 Assemble the Drive Gear Screw 26 Drive Gear Lock Washer 46 Drive Gear Cup 45 and Drive Gear Screw O Ring 27 4 Grasp the Drive Shaft 53 in a vise pinion end down Place assembled Drive Shaft Screw Unit into the Drive Shaft screw and head down Lubricate the inside diameter of the Drive Shaft with Ingersoll Rand No 130 Grease 5 Slide the Front Drive Gear Bearing 44 into the Drive Shaft 6 Lubricate with Ingersoll Rand No 130 Grease and install the Driving Clutch Jaw teeth facing up and Driven Clutch Jaw teeth acing down into the Drive Shaft 7 Insert the Clutch Spring 41 into the Drive Shaft nsert the Clutch Spring Cup 40 into the Drive Shaft 9 Press the inserted parts into the Drive Shaft and install the Clutch Spring Cup Retainer 39 10 Using an arbor press press the Piston Seal 51 cover side out into the Piston until it is flush with the piston face 11 Install the Piston 49 onto the Drive Shaft until the Rear Drive Shaft
41. 5 Remove the Drive Pinion Washer 22 and the Drive Pinion 23 6 Slide the Pinion Spring Sleeve 24 and the Pinion Spring 25 off the Drive Shaft 7 Insert a 3 8 square drive extension through the Motor Housing Cover to hold the Rotor 13 from turning Using a 5 16 8 mm x 8 203 mm long hex wrench inserted into the end of the Drive Shaft unscrew the Drive Gear Screw 26 8 Unscrew and remove the Drive Housing Cap Screws 28 and Lock Washers 29 9 Tapthe Drive Housing 30 with a plastic hammer to help dislodge it from the Gear Case 58 WARNING Failure to follow this procedure could result in injury to personnel 30 5 Lubricate the Front Drive Gear Bearing 44 with Ingersoll Rand No 130 Grease 6 Lubricate the pinion end of the Drive Shaft with Ingersoll Rand No 11 Grease 7 Wipe a thin film of Ingersoll Rand No 130 Grease in the bore of the Drive Housing 58 8 Roll the Piston Return Spring 56 in Ingersoll Rand No 130 grease 9 Coat the outside of the Piston 49 with Ingersoll Rand No 130 Grease 10 Place the Drive Housing in an arbor press piston end up Apply pressure to the Piston 49 to compress the Piston Return Spring 56 before removing the Bulkhead Retainer 34 11 Using a screwdriver remove the Bulkhead Retainer Ease off the arbor press CAUTION Make sure the tension of the spring pushes the Bulkhead out of the Drive Housing before removing the Drive Housing from the
42. 80859 1 29 pem c 878 LEG m 254 VARE BER EN LI E BEG yasan 370 15 8 60 8 9 09855 LT ULI 9 1 TT 9L cO6 06 VIER S 1540 FELL EEL L rl zj O SLE 8 5 WBZ C 091 P 01 970 DZ SL OLW mere a ED s98 seg 081 Y 8 00z HEEN EE m 98 cs9 BEG h CAIN ldN 1 11 1 1 ap s s oyy eor i NYDN COBEY 2 54 OVALE HH ES En VIELSEN LIG TdN 8l L zo gd L vesen sr 2 9 0081 on i 0891 Cv PF 5195 TPA832 5 21 03531480 ed13 SS815 SMB 618 PER MCA L W JIC 379 SRV125 1242 s JIC370 72472 IN JIC 37 1 T OUT JIC 37 14 NET 1 12 NPT EE 1 4
43. Drive Housing Plug and replace it with a suitable Tubing Line The tubing must vent at a safe location and must not be interconnected with any other exhaust lines which might introduce a back pressure on the Drive Housing Vent Typical Stationary Installation Shown with SS815 Starter Air Pressure Guage Relief Valve set at 15 5 above Regulator Setting For gas operating the Relief Valve outlet must be connected into a gt Starter Control Valve SMB 618 4 Hose 4 Hose safe area 5 JIC 37 Adapter 1 4 N PT JIC 37 Adapter 1 1 2 N PT OUT Port JIC 37 Adapter 1 4 N PT MA K LI SRV150 1 1 2 Hose IN o 1 1 2 Relay Valve M A a a7 Pressure regulator maximum setting not to Lubricator VA BE exceed pressure rating shown on name plate NL 24 8 H High Pressure Supply Standard high pressure system air or gas Use when supply pressure is over d pressure rating of starter For natural gas operation starter main exhaust must be m piped away Dwg TPA842 2 03531480_ed13 To pipe the Drive Housing Plug remove the Drive Housing Plug and replace it with a suitable tubing line The tubing must vent at a safe location and must not be interconnected with any other exhaust lines which might introduce a back pressure on the Drive Hou
44. a bullet for every four tools in service 03531480 ed13 27 Series SS850 Starters Exploded Diagram Dwg TPA820 3 28 03531480 ed13 Series SS850 Starters Parts List Item Part Description Part Number Item Part Description Part Number 1 Motor Housing 28 Drive Housing Cap Screw 8 SS800 744 with 2 1 2 Tapped Exhaust SS800 40 29 Drive Housing Cap Screw with 2 1 2 SAEJ518C Lock Washer 8 CE210605 Flanged Exhaust 358007140 30 Drive Housing Kit SS850 K300 2 Motor Housing Cover Assembly 31 Drive Housing O Ring 55850 244 with 1 1 2 Tapped Inlet SS800 A102 32 Front Drive Shaft Bearing SS850 363 with 1 1 2 SAEJ518C Flanged 33 Drive Housing Seal SS800 273 Inlet 33000A 0 33A Drive Housing Vent Plug P250 546 Housing Cover Plug 3 HSSPPS 3 34 Bulkhead Retainer SS500 181 4 Motor Housing Cover Cap Screw 4 SS800 25 35 Bulkhead Kit SS850 K150 4A Motor Housing Cover Cap Screw 1 36 Outer Bulkhead O Ring SS850 152 Washer 4 SS800 26 t 37 Inner Bulkhead O Ring SS805 151 5 Cylinder Kit SS800 K3 39 Clutch Spring Cup Retainer SS850 366 t6 End Plate Alignment Pin 2 510 669A 40 Clutch Spring Cup 55850 367 7 Cylinder Alignment Pin SS800 99 41 Clutch Spring 55850 583 8 Cylinder O Ring 4 SS800 67 42 Clutch Jaw Kit 9 Rear End Plate for SS850RD Models SS
45. clean or remove Check for ice build up Melt ice and reduce moisture build up to Starter Damaged Motor Assembly Foreign material in Starter Drive Replace Motor Assembly Foreign material in Starter Drive Damaged or worn Drive parts Check Drive components and replace if necessary nadequate lubrication Check the lubricator inlet hose fitting and oil supply hose to make sure they are vacuum tight and free of leaks Tighten all joints and replace lubricator if necessary Starter drive does not engage ring gear or engages and disengages ring gear very slowly Clogged control hoses Remove the control hoses attached to the Drive Housing and clean them by blowing compressed air through them WARNING Firmly secure the hose end before turning on the air Make certain nooneisin line with the discharge end of the control hose Clogged or faulty Control Valve Remove and inspect the Control Valve or install a new Control Valve if necessary Broken Clutch Jaws or other parts Disassemble Drive Housing and replace broken parts Motor runs pinion engages but does not rotate Broken Shaft Gearing or Clutch Jaws Disassemble Drive Housing and replace broken parts Excessive butt engagements Dry Drive Pinion Spline Remove Drive Pinion and lubricate the Drive Pinion and the helical spline of the Drive Shaft Refer to Disassembly of the Drive Housing Par
46. frie SE 294 0687 6 Or Beles Be CH O Wirt lel a 8v1 J O SLE von qe mi ldN 8 2 1 Z 7 AHN E 998 TEX 89 SA le W 09 ETSL pe 6 EE Y HELE LN c 09 amp 9 f PULS OLW NE EL AdNZ LLL Z AL Et zroug 99 0081 0891 kl trl 19 FERGEN bs eve HEN TPA832 5 E 13 03531480_ed13 55815 SMB 618 4 FEDRE JIC 37 SRV125 1242 SS mmm JIC 37 JIC 37 a T 1 4 NPT TUNE SS JIC 37 1 4 NPT i mem 1 1 2 NPT 3 3 q 6J SA AE U f 1 EN Zi titt a 1 8 27 PTF SAE Pe 1 1 2
47. no air or gas is escaping Measure the dimension from the face of the Drive Shaft Pinion 23 to the face of the mounting flange It should be 2 23 32 69 0 2 0 mm for 32 16 Slide the Piston Return Spring 56 onto the Drive Shaft and snap it into the front of the Piston so that it is against the Large Drive Shaft Bearing Retainer 47 17 Lubricate and insert the assembled Drive Shaft into the Drive Housing 18 Using O Ring lubricant lubricate and install the Outer Bulkhead O Ring 36 and the Inner Bulkhead O Ring 37 on the Bulkhead 35 19 Slide the Bulkhead onto the Piston 20 With the Drive Housing in the arbor press press down on the rear face of the Piston NOTICE Feel the underside of the Drive Housing to make sure the Drive Shaft passes through the Bearing Using a screwdriver install the Bulkhead Retainer 34 WARNING Make sure the Bulkhead Retainer is properly seated in the Motor Housing groove before easing off the arbor press 21 Remove the Drive Housing from the arbor press 22 Using O Ring lubricant lubricate and install the Drive Housing O Ring 31 in the groove of the Drive Housing 23 Position the assembled Motor Housing and Gear Case on a workbench Assembled unit must be upright to accept the Drive Housing 24 Carefully position the assembled Drive Housing 30 on to the Gear Case so as not to damage the Piston Seal Align the punch marks of the Gear Case and Drive Housing 25 I
48. or a light motor oil such as SAE 10 or 10W 03531480_ed13 Mounting Dimensions for Series SS815 and SS825 Starters pu suoisuauitq ww leng sq156 5y Leb 3Y6I3M ByelS ualoay ol Bundwane aloyaq suononasu Y Peay aseald 9 payloads 551 49930 ssalur peddius aq IIIM DZ0 UMOYS uoneyuauo piepueis 5 suod Ionuo aq eusoddo aloH Bununow iod uo paseg 51 epo uohe1uauO 6ulsnoH AU pinjj 61558 5 8 4 o pesodx3 si 493535 y 849 suoneor ddy 104 paAolddv jou aie slapoW 353U1 E anu uotuld 99 1 uone1od 19IUI BuisnoH 3AUg epo uoneluauO 6uueaD jsneux3 JelelS 99 1 Mer cow ec 970 ILE Y 08 D 51855 6ulsnoH AUA 241 Jo ap s 1 ddN au1 uo s110d 011U0J JO 195 BY esp UMOG palulod 1SneUX 24 YUM 3U Bu eui uo pallelsul aq PINOYS SHAS L saJON uoneloy pueH 14619 c uoneoy eura PueH 91 9384 1230 Bury uoddns lead 104 se ejd z 091 9990 59 p4L S L 0LW OZZL OTLL 9NIqoD 1300N 2 1 94 068v 66v ieu 35 suondo uone1uauO f Piw LZD 4 C Ce over 0ZzE 3sneyx3 1 LANGT ool deg li OS au 404109 03 Buisno en 9 8 iio so 3 Ca wsz Luoldld 1 1 sac Zs T OLD eo 19lld 007 59815 log uonpauuoD luO 855 oneudm 90 dL 991 5nld usA v PNO 404 onuoD 1dN gl SoL 2958
49. 09L51 Models 558501 13 52 Road Splash Deflector SM450 A735 24 Pinion Spring Sleeve SS800 335 Air Strainer SM450 A267AT 25 Pinion Spring In Line Lubricator NL 24 8 or SS850RD Models SS850R 419 Lubricator HDL2 or SS850LD Models SS850L 419 Tune up Kit includes illustrated parts 26 Drive Gear Screw SS800 179 2 7 8 10 10A 4 11 15 18 24 25 SS850 TK2 27 Drive Gear Screw O Ring SS800 176 27 31 33 34 36 37 39 50 51 60 and 61 Not Illustrated Indicates Tune up Kit part To keep downtime to a minimum it is desirable to have on hand certain repair parts We recommend that you stock one pair or set of each part indicated by a bullet for every four tools in service 03531480 ed13 29 Maintenance Disassembly Assembly Instructions WARNING Always wear eye protection when operating or performing any maintenance on this starter Always turn off the air supply and disconnect the air supply hose before installing removing or adjusting any accessory on this starter or before performing any maintenance on this starter Lubrication Each time a Series SS815 55825 or 55850 Starter is disassembled for maintenance or repair lubricate the starter as follows For temperatures above 32 F 0 C use a good quality SAE 10 non detergent motor oil For temperatures below 32 F 0 C use diesel fuel 1 Lubricate all O Rings with O Ring lubricant 2 Lubricate the Drive Gear 62 wit
50. 50 f ES NERIS 1 2 3 4 2 3
51. 55660 A674 E SM450 A375 1 1 2 3 dich OUT PUE 1 4 m JIC 37 77 1 1 4 4 F NPT UC 370 ne VA NPT 1 1 2 Y JC 3 J o E 1 12 NPT H i NL 24 8 SRV150 1 1 2 ta V LAS CA BED EDU X FYLT WOMEN CN MURCA VF 4 SS660 A674 2 i SM450 A375 5 3 1 2 3 7475 Qu t IN JIC 37 VUA TIT NET 3 14 NPT 1 1 2 VA N PT 120 150 Psig mE o JIC 377 1 1 2 475 NPT NL 24 8
52. 800R K587 for SS850RD Models SS800R 12 for SS850LD Models SS800L K587 for SS850LD Models SS800L 12 44 Front Drive Gear Bearing SS800 278 t10 Rear Rotor Bearing SS800 24 45 Drive Gear Cup SS800 177 10A Rotor Shaft O Ring C321 606 46 Drive Gear Lock Washer SS800 180 11 Rear Rotor Bearing O Ring HRA20A 990 47 Large Drive Shaft Bearing Retainer 55850 107 12 Rotor Clamp Nut SS800 65 49 Piston Kit SS850 K703 13 Rotor 55825 53 50 Piston O Ring SS850 337 14 Rotor Clamp Nut Screw SS800 63 51 Piston Seal SS800 273 1 15 Vane Packet set of 5 Vanes SS800 42A 5 53 Drive Shaft Kit 16 Front End Plate SS800G 11 for SS850RD Models SS850R K8 17 Motor Wave Washer 2 SS800 224 for SS850LD Models SS850L K8 18 Front Rotor Bearing SS800 22 54 Rear Drive Shaft Bearing Kit 19 Rotor Pinion Retaining Screw SS800 732 includes bearing and retainer 3589 0 K399 20 RotorPinion 56 Piston Return Spring SS850 700 or SS850RD or SS850LD Models SS850D 17 58 Gear Case 55850 37 21 Drive Pinion Retaining Screw 59 Drive Gear Bearing Retainer SS800 361 or SS850RD Models SS850R 394 60 Drive Gear Shaft Bearing Retainer SS800 632 or SS850LD Models SS850L 394 t 61 RearDrive Gear Bearing SS800 359 22 Drive Pinion Washer 55800 725 62 Drive Gear SS850D 9 23 Drive Pinion Nameplate SS800 301 or SS850GD09R51 and Nameplate Screw 4 R4K 302 SS850FGD09R51 Models 1234 Relay Valve SRV150 or SS850GD09L52 and Muffler 55660 674 SS850FGD
53. BELT PSUR MMM AEK OEY ACY GBR FLOUR 89 ru aa 8 LY CREE 9 0 E d 08 9 SI8SS pee E AGERE Fr 0721 o OL ARD LEIZA AA AKE CORI CO BUR EE HEL AR 20 VARBERG I AEA RS P 820899 I 8288 PAR IG 28 gt 9741 ps CZ 444 ze Oter ENE F ove sv 22143 1dN 8 7 1 CAN Elder 0 bis a feos om BIG AER sms sanset 3 og sez Usu f z s TF ve 9 IT 8 4 0991 d iege owe cy FE Ly 6 0 72025 855 E gt 48 S 8858 09 8 ND 4 98 velg PME nur 14 81 1 NM 01 L 9 986 88 9 591 T S6lv LETE MOB VA GL OVN AVEC IE N LIGY 8 1 TPA1325 1 03531480_ed13 20 7 55850 pul ww OF 591 99 68 sz FERAE RSL TER HE EG CP ag SEI 9 XU ERR BL rs 320 SV Ue EE n 1 CO SY BED S KRO 1ENETYOM EAR OMS BW KAI CO 4 edd FIN MEG BIER n YARD UGPEEP SON BY TOWs a Ec GEL AEA GEN PIL 3 062 22 2 BIN 62 4 888 ORT Co D ssl lii TABBEN SIT 2 092 4 BE Uses PI
54. Bearing seats into the Piston 12 Using a thin flat blade screwdriver to assist in this operation coil the Large Drive Shaft Bearing Retainer 47 into the groove of the Piston to retain the outer race of the Drive Shaft Bearing 13 Lubricate the Piston O Ring 50 and install it in the groove of the Piston 14 Position the Drive Housing in an arbor press pinion end down and install the Drive Housing Seal 33 into the Drive Housing NOTICE Press the Seal into the Drive Housing so that the lip ofthe Seal faces towards the Drive Pinion 2 15 Using a sleeve that contacts the outer race of the Front Drive Shaft Bearing 32 press the Bearing into the Drive Housing until it seats For Models SS815 and SS825 drop the Piston Return Spring Seat 57 on top of the Front Drive Shaft Bearing Test and Inspection Procedure 1 Clutch Ratcheting Turn the Drive Shaft Pinion 23 by hand in the direction of Starter rotation The clutch should ratchet smoothly with a slight clicking action 2 Motor and Gearing Freeness Turn the Drive Shaft Pinion 23 opposite the direction of Starter rotation The Drive Shaft Pinion should turn by hand 3 Pinion Engagement Apply 50 psig 3 4 bar 345 kPa pressure to the engagement In Port Drive Shaft Pinion 23 should move outward and air or gas should escape from the Out Port Plug the Out Port and apply 150 psig 10 3 58 034 kPa pressure to the In Port Check and make sure
55. CN od 03005 pueH ye1 LL 1dN 81 1 i 5 sc 081 Sa2eld 998 dAL 89 1 1 w 09 H i sapis yoq uon2auuo Jojeouqn AdN Z LLL Z LL LoL vu 39890 10104 Ul JOH buuueg od IonuoD 8 bs 8 0 ssa V TdN 8L b L zoll g L 104 6nld adig 9 0 99 lias 0081 089L r S 19 Dwg TPA832 5 03531480_ed13 Typical Vehicular Installation Shown with SS815 Starter N 4 Hose Starter Control Valve SMB 618 Brass ToRelay Valve From Starter 4 Hose Air Pressure Guage EN Air Supply from Compressor Check Valve Control Valve JIC 37 SRV125 1242 IN Port JIC 37 JIC 37 Adapter Adapter 1 4 N PT 1 1 2 N OUT Port JIC 379 Adapter 1 4 N PT 1 1 2 Hose N 1 1 2 n N PT j E i i 1 Air Receiver oo Tank en Supply Line Pipe Plug 1 8 27 PTF SAE Socket Drive NOTE Use IR SMB 441 Sealant on all Pipe Connections SS660 A674 Muffler or SM450 A735 Road Splash Deflector Dwg TPC444 4 Air Gas Starter Air Gas Starter SRV 150 1 1 2 Relay Valve Vpe For natural gas operation Starter Main Exhaust must be piped away To pipe the Drive Housing Vent remove the
56. ES SuMP 8 1 4 4 T 9 1 1 2 24 10 1 1 2 24 11
57. P6567 03531480 Edition 13 January 2014 Starters Series SS815 SS825 and SS850 Installation and Maintenance Information e Installation and Maintenance Information OD Save These Instructions dam Ingersoll Rand Product Safety Information Intended Use These air starters are intended for use in starting reciprocating internal combustion engines These starters are designed to be operated from a remote location after proper installation on the engine requiring starting For additional information refer to Air Starters for Internal Combustion Engines Product Safety Information Manual Form 45558624 Manuals can be downloaded from ingersollrandproducts com Placing Starter in Service NOTICE For natural gas operation starter main exhaust must be piped away To pipe the drive housing vent remove the drive housing plug and replace it with a suitable tubing line The tubing must vent Lubrication Proper lubrication is essential for top performance and maximum durability of a Starter Two lubrication systems are recommended Ingersoll Rand No HDL2 Lubricator For Starter installations with cranking cycles of less than 10 seconds Install as shown in Dwg TPB978 See Installation of HDL2 Lubricator on EN 4 Lubricate with diesel fuel or 10W non detergent motor oil Ingersoll Rand No NL 24 8 In Line Lubricator For Starter installat
58. PD1495 24 03531480_ed13 Front End Construction of Series SS850 mala N ut UMOUS SZ8SS pue 185 S4 HLIS 09855 pue GZ8SS GL8SS SAAS LL EL 8S 91 81 OT 6L ov T9 11 al vl VOL Dwg TPA853 4 25 03531480 ed13 Series SS815 and SS825 Starters Exploded Diagram Dwg TPA778 6 03531480 ed13 Series SS815 and SS825 Starters Parts List Item Part Description Part Number Item Part Description Part Number 1 Motor Housing 28 Drive Housing Cap Screw 8 SS800 744 with 2 1 2 Tapped Exhaust 55800 40 29 Drive Housing Cap Screw CE210 605 with 2 1 2 SAEJ518C 55800 140 Lock Washer 8 Flanged Exhaust 30 Drive Housing Kit SS825 K300 2 Motor Housing Cover Assembly 31 Drive Housing O Ring 55800 244 with 1 1 2 Tapped Inlet 55800 102 31 Drive Housing Vent Plug P250 546 with 1 1 2 SAEJ518C Flanged 32 Front Drive Shaft Bearing Inlet 0A202 or SS815B Models 55800 363 3 Housing Cover Plug 3 HSSPPS 3 or SS825C Models SS850 363 4 Motor Housing Cover Cap Screw 4 SS800 25 33 Drive Housing Seal SS800 273 4A Motor Housing Cover Cap Screw 55800 26 34 Bulkhead Retainer 55800 181 Washer 4 35 Bulkhead Kit SS800 K150 5 Gylinder Kit SS800 K3 1 36 Outer Bulk
59. e 9 bearing end up onto the rotor shaft 5 Screw the Rotor Clamp Nut 12 onto the rotor shaft with the shoulder toward the bearing Tighten the nut until there is 001 02 mm to 003 07 mm clearance between the Rear End Plate and Rotor 6 Using a 5 32 4 mm hex wrench tighten the Rotor Clamp Nut Screw 14 After tapping the End Plate away from the rotor face with a plastic hammer recheck the clearance between the Rear End Plate and Rotor 03531480 ed13 10 Remove the Large Rear Rotor Bearing O Ring 11 11 Remove the Rear End Plate 9 from the rotor shaft 12 Remove the Small Rear Rotor Bearing O Ring 10A from the rotor shaft 13 If the Rear Rotor Bearing 10 needs to be replaced remove it from the Rear End Plate 14 Push the Cylinder 5 out of the Motor Housing 15 Remove the Cylinder O Rings 8 from the Cylinder Gear Case 1 Place the Gear Case 58 on a workbench 2 Using retaining ring pliers and working through the access holes in the gear web remove the Drive Gear Bearing Retainer 59 3 Pull the Drive Gear 62 out of the Gear Case 4 Do not disassemble the Drive Gear of Series 55815 55825 or SS850 If the Drive Gear is defective install a new or factory rebuilt unit 5 Using a retaining ring pliers remove the Drive Gear Shaft Bearing Retainer 60 6 Remove the Rear Drive Gear Bearing 61 from the Drive Gear 7 Checkthe two End Plate Alignment Pins 6 If they are bent or br
60. e other protruding End Plate Alignment Pin 6 in the face of the Cylinder should align with the dowel hole in the Front End Plate 16 Insert the two Motor Wave Washers 17 into the Front End Plate well 17 Install the Front Rotor Bearing 18 into the Front End Plate well 18 Install the Rotor Pinion 20 on the rotor shaft so that the lugs on the Pinion engage those on the shaft 19 Screw the Rotor Pinion Retaining Screw 19 into the rotor shaft and tighten to 90 ft Ib 122 Nm torque 20 Using O Ring lubricant lubricate and install the Rear Rotor Bearing O Ring 11 onto the Rear Rotor Bearing 21 Check freeness of the motor by turning the Rotor Pinion If necessary tap the Front End Plate with a soft hammer to align the motor 31 22 Align the punch marks on the Gear Case 58 Motor Housing 1 and Motor Housing Cover 2 and assemble as follows a Grasp the Gear Case 58 in a vise by the Drive Gear Shaft b Insert the pinion end of the motor into the Gear Case Using a soft hammer tap the Motor Housing 1 until it seats C Position the Motor Housing Cover 2 on the Motor Housing Using a soft hammer tap the Motor Housing Cover until it is seated on the Motor Housing NOTICE Screw a 12 305 mm piece of 1 1 2 38 mm pipe into the air inlet to act as a handle to help align the Motor Housing with the Motor Housing Cover and Gear Case d Lubricate the threads and install the Motor Housing Cover Cap Screws
61. e Corporation ata safe location and must not be interconnected with any other exhaust lines which might introduce a back pressure on the drive housing vent CAUTION When an HDL2 Lubricator is used make certain that the oil supply line pressure is no greater than 5 psi If there is pressure on the line the Lubricator will continuously leak lubricant through the Starter and out of the exhaust 5 The efficiency of an Air Starter can be greatly impaired by an improper hook up Hoses smaller than those recommended will reduce the volume of air to the motor and the use of reducers for piped away applications in the exhaust port will restrict the exhaust causing back pressure to the motor resulting in reduced performance The number of tees and elbows and the length of the supply line should be kept to a minimum Use 1 1 2 24 hose or pipe for supply lines upto 15 feet long use 2 hose or pipe if the supply line is over 15 feet long 6 A leak in any of the connections in live air lines means that the system will drain overnight and will have to be re pressurized the next morning by use of another vehicle or compressor Make your connections bubble tight to avoid unnecessary costs and delays On all threaded connections throughout the system use Ingersoll Rand No SMB 441 Sealant non hardening No 2 Permatex or Loctite Pipe Sealant Always run your air supply line from the side or top of the receiver never at or near the bottom Moistur
62. e in the air collects at the bottom of the receiver resulting in damage which could cause the valves to become inoperative Periodically open the petcock at the bottom of the tank to drain the water 03531480 ed13 Orientation of the Air Starter If the factory orientation will not fit your engine due to radial location of the Drive Housing or location of the inlet and or exhaust ports reorient the Starter as follows 1 Lookat the dimension illustration and note that the Drive Housing 30 can be located in any one of sixteen radial positions relative to the Gear Case 58 The exhaust port Motor Housing 1 can be located in any one of four radial positions relative to the Gear Case and the air inlet Motor Housing Cover can be located in any one of four radial positions relative to the exhaust port Also the Drive Housing can be installed on the engine bell housing in any one of three radial positions NOTICE Do not separate the Drive Housing from the Gear Case during orientation or installation 2 Study the engine mounting requirements and determine the required orientation of the Drive Housing relative to the Gear Case If the Drive Housing has to be reoriented remove the eight Drive Housing Cap Screws 28 and rotate the drive housing to its required position Reinstall the Drive Housing Cap Screws and tighten them to 28 ft lb 38 Nm of torque NOTICE Do not separate the Motor Housing from the Motor Housing Cover durin
63. g orientation or installation 3 Now that you have the Drive Housing properly oriented relative to the Gear Case notice whether or not the exhaust port will be at the bottom and whether or not the inlet port will be favorably located for hose installation If either or both of these members must be reoriented remove the four Motor Housing Cover Cap Screws 4 and rotate the Motor Housing and or Motor Housing Cover to its desired position Reinstall the Motor Housing Cover Cap Screws and alternately tighten them to 60 ft lb 81 4 Nm of torque Mounting the Air Starter 1 Study the Piping Diagram We strongly recommend that the Starter be connected exactly as shown 2 The air receiver tank for a Starter installation must have a working pressure capability equal to or greater than the maximum pressure at which the Starter will be operated WARNING Bleed off the air pressure through a valve or petcock Do not remove the plug from the tank while the tank is still pressurized 3 If you are going to connect to a receiver tank that is already in service bleed off the air pressure by opening the drain valve Drain off any water that may have accumulated in the bottom of the tank NOTICE Make certain the connection between the SRV150 Starter Relay Valve and the Receiver Tank is made to the inlet side of the Relay Valve indicated by the word IN cast on the valve body 03531480 ed13 4 Using 8 1 1 2 short nipple instal
64. h 8 oz of Ingersoll Rand No 130 Grease Lubricate the Vanes 15 with 10W non detergent oil 4 Lubricate the inside diameter of the Drive Shaft 53 with Ingersoll Rand No 130 Grease Disassembly General Information 1 Do not disassemble the starter any further than necessary to replace worn or damaged parts 2 When grasping a part in a vise always use leather covered or copper covered vise jaws to protect the surface of the part and help prevent distortion This is particularly true of threaded members 3 Do not remove any part which is a press fit in or on a subassembly unless the removal of that part is necessary for replacement or repairs 4 Always have a complete set of seals and O Rings on hand before starting any overhaul of a starter Never reuse old seals or gaskets 5 Always mark adjacent parts on the Motor Housing Cover 2 Motor Housing 1 Gear Case 58 and Drive Housing 30 so these members can be located in the same relative position when the Starter is reassembled Drive Housing 1 Remove the rear Motor Housing Cover Plug 3 from the rear of the Motor Housing Cover 2 2 Grasp the Drive Pinion 23 in a vise with the Starter supported on the workbench NOTICE Models SS815RB SS825RC and SS850RD have a left hand thread Models SS815LB SS825LC and SS850LD have a right hand thread 3 Using a wrench remove the Drive Pinion Retaining Screw 21 4 Remove the starter from the vise
65. head O Ring 55800 152 6 End Plate Alignment Pin 2 510 669A 1 37 nner Bulkhead O Ring SS800 151 7 Cylinder Alignment Pin 55800 99 139 Clutch Spring Cup Retainer 55800 366 8 Cylinder O Ring 4 55800 67 40 Clutch Spring Cup 55800 367 9 Rear End Plate t41 Clutch Spring 55800 583 for SS815RB or SS825RC Models SS800R 12 42 Clutch Jaw Kit for SS800LB SS815LB or or SS815RB or SS825LC Models 328000512 SS825RC Models 10 Rear Rotor Bearing 55800 24 or SS815LB or Rotor Shaft O Ring C321 606 SS825LC Models Rear Rotor Bearing O Ring HRA20A 990 44 Front Drive Gear Bearing 55800 278 12 Rotor Clamp Nut 55800 65 45 Drive Gear Cup 55800 177 13 Rotor 55825 53 46 Drive Gear Lock Washer 55800 180 14 Rotor Clamp Nut Screw 55800 63 47 Large Drive Shaft Bearing Retainer 55800 107 15 Vane Packet set of 5 Vanes SS800 42A 5 49 Piston Kit SS800 K703 16 Front End Plate SS800G 11 1 50 Piston O Ring 55800 337 17 Motor Wave Washer 2 55800 224 51 Piston Seal SS800 273 18 Front Rotor Bearing 55800 22 53 Drive Shaft Kit 19 Rotor Pinion Retaining Screw 55800 732 for SS815RB or 20 Rotor Pinion SS825RC Models odd or SS815RB SS800LB or for SS815LB or SS815LB Models acd 558251 Models SERERE or SS825RC or 54 Rear Drive Shaft Bearing Kit SS825LC Models 95823617 includes bearing and retainer 55800399 21 Drive Pinion Retaining Screw 56 Piston Return Spring 55800 700 or SS815RB or SS825RC 57 Pis
66. ions with cranking cycles more than 10 seconds Install as shown in Piping Diagrams Lubricate with a good quality 10W non detergent motor oil Adjust the Lubricator to flow 1 to 3 drops per second Installation NOTICE For maximum performance read this manual priorto the installation or operation of Series SS815 SS825 and SS850 Starters General Information 1 We recommend that on all vehicular installations and on stationary engines subject to vibration that hoses of the specified diameter be used instead of rigid pipe connections to the starter Vehicle and engine vibration will soon loosen rigid pipe connections whereas hoses will absorb the vibration and connections will remain tight 2 This starter is designed for flange mounting at the inlet All piping hoses and fittings must be clean and free of dirt and foreign material during installation 3 Inthe actual mounting of an Air Starter it is best to have the hose connections already made at the receiver and to have the starter end of the hose handy for attaching to the Starter 4 Engine design often demands that the starter be mounted underneath in extremely close quarters and even though two of the mounting bolt holes are easy to reach the third one is often less accessible To install a starter the following tools are required aregular ratchet wrench sockets universal joint socket extension and a single or double end box wrench Registered trademark of Loctit
67. l the SRV150 Starter Relay Valve on the end of the receiver tank as shown in Dwg TPC444 4 on EN 7 5 Install the No SMB 618 Starter Control Valve on the dash panel for vehicular installations or some other appropriate panel for stationary installations 6 Attach No TA STR 100 Starter Instruction Label to the control panel adjacent to the Starter Control Valve 7 Mount the No 150BMP 1064 Air Pressure Gauge on or adjacent to the control panel It should be located where it is readily visible to the operator of the Control Valve NOTICE When connecting the Starter Control Valve to the Relay Valve make certain the hose is connected to the SUMP side of the Starter Control Valve 8 Connect the Starter Control Valve to the Relay Valve with 1 4 4 hose Install a Tee in this line with a short feeder hose to the Pressure Gauge 9 Runa piece of heavy duty garden hose or some other similar large diameter hose from the Relay Valve on the receiver to the starter location on the engine to determine the exact length of 1 1 2 24 air hose required 10 Attach the 1 1 2 24 air hose to the outlet side of the Relay Valve and run the hose through the frame etc to its final position at the starter location 11 At this point determine whether or not it is practical to attach the hose to the Starter before or after the Starter is actually mounted n many cases it may be necessary to attach the hose to the Starter before moun
68. ng purposes it may be desirable to bar over the engine in such a manner that any given piston can be stopped at any given location This is very easily done with a SS815 SS825 or SS850 Starter 1 Disconnect the 1 4 4 hose at the OUT port on the Drive Housing and plug the hole in the Drive Housing with a 1 4 pipe plug 2 Remove the 3 8 pipe plug from the center of the Motor Housing Cover 3 Engage the Drive Pinion with the flywheel by applying pressure to the IN port on the Drive Housing 4 Insert a 3 8 square drive wrench through the hole in the Motor Housing Cover to engage the square drive recess the rear of the Rotor 5 Manually rotate the Rotor until the engine is cranked to its desired position INSTALLATION OF HDL2 LUBRICATOR AIR SUPPLY HOSE LUBRICANT SUPPLY HOSE Dwg TPB978 Mount the HDL2 Lubricator as follows 1 If you are going to mount the HDL2 Lubricator on the Starter remove one of the 3 8 pipe plugs from the inlet boss on the Starter and replace it with the HDL2 If you are going to mount the HDL2 at a remote location use two U bolts and base clamp available for the Lubricator 2 If you mounted the HDL2 at a remote location install a 1 4 4 hose from the end of the Lubricator having both a male and female thread to one of the 3 8 pipe tapped holes on the Starter inlet boss The HDL2 Lubricator is self priming and may be ins
69. nstall the Drive Housing Cap Screw Lock Washers 29 and the Drive Housing Cap Screws 28 and tighten to 28 ft lb 38 Nm torque 26 Insert a 3 8 10 mm square drive extension bar through the hole in the Motor Housing Cover to prevent the Rotor from turning Using a 5 16 8 mm x 8 203 mm long hex wrench inserted into the end of the Drive Shaft tighten the Drive Gear Screw 26 to 29 1 15 39 3 Nm torque 27 Using Ingersoll Rand No 11 Grease Lubricate and slide the Pinion Spring 25 and the Pinion Spring Sleeve 24 over the Pinion end of the Drive Shaft 28 Lubricate the pinion end of the Drive Shaft with Ingersoll Rand No 11 Grease and install the Drive Pinion 23 29 Grasp the Drive Pinion in a vise with the Starter supported on a workbench 30 Place the Drive Pinion Washer 22 onto the Drive Pinion Retaining Screw 21 Install the Drive Pinion Retaining Screw into the end of the Drive Shaft and tighten it to 80 ft lb 108 5 Nm torque for 55815 and 55825 Starters and 125 ft lb 169 5 Nm torque for 55850 Starters NOTICE Models SS815RB SS825RC and SS850RD have a left hand thread Models SS815LB SS825LC and SS850LD have a right hand thread Remove the Starter from the vise 31 Install the rear Motor Housing Cover Plug 3 and tighten securely Models 55815 55825 and 8 3 4 222 2 0 mm for Model 55850 Remove the pressure from the In Port Measure the distance from the face of the Drive Shaft Pinion
70. oken remove them from the Cylinder and press in a new pin or pins 8 Check the Cylinder Alignment Pin 7 If it is bent or broken remove it from the Cylinder and press in a new pin 9 Using O Ring lubricant lubricate and install the two inside Cylinder O Rings 8 10 Position the Motor Housing 1 vertically on two blocks of wood locating slot up 11 Using a plastic hammer tap the Cylinder 5 into the Motor Housing making sure the Cylinder Alignment Pin 7 seats into the slot of the Motor Housing 12 Using O Ring lubricant lubricate and install the two outside Cylinder O Rings 8 13 For Right Hand Rotation Starter Insert the Rotor 13 into the Cylinder pinion end toward the Cylinder Alignment Pin NOTICE Make sure the protruding End Plate Alignment Pin 6 in the Cylinder aligns with the dowel hole in the Rear End Plate 9 numbered SS800R 12 Make sure the air ports of both the Cylinder and the Rear End Plate align For Left Hand Rotation Starter Insert the Rotor 13 into the Cylinder pinion end away from the Cylinder Alignment Pin NOTICE Make sure the protruding End Plate Alignment Pin 6 in the Cylinder aligns with the dowel hole in the Rear End Plate 9 numbered SS800L 12 Make sure the air ports of both the Cylinder and the Rear End Plate align 14 Lightly lubricate each Vane 15 and insert one in each of the rotor vane slots 15 Slide the Front End Plate 16 over the pinion end of the Rotor Th
71. rive Shaft b Press the Rear Drive Shaft Bearing 54 off the Drive Shaft 03531480 ed13 Motor Housing 1 Unscrew and remove the Motor Housing Cover Cap Screw 4 2 Pull the Motor Housing Cover 2 from the motor Housing 1 It may be necessary to dislodge the Motor Housing Cover by tapping it with a plastic hammer 3 Tap the Gear Case 58 with a plastic hammer to dislodge it from the Motor Housing 4 Grasp the Rotor Pinion in a vise and using a wrench remove the Rotor Pinion Retaining Screw 19 5 Remove the Rotor Pinion 20 from the rotor shaft 6 Slide the Front End Plate 16 Front Rotor Bearing 18 and Motor Wave Washers 17 off the rotor shaft 7 Remove the Rotor 13 and Rear End Plate 9 from the Cylinder 8 Remove and examine each Vane 15 Install a new set of Vanes if any Vane is cracked spalled or worn to the extent that its width is 15 16 24 mm or less at either end 9 Grasp the Rotor in a vise Using a 5 32 4 mm hex wrench loosen the Rotor Clamp Nut Screw 14 Unscrew and remove the Rotor Clamp Nut 12 Assembly General Instructions 1 Always press on the inner ring of a ball type bearing when installing the bearing on a shaft 2 Always press on the outer ring of a ball type bearing when pressing the bearing into a bearing recess 3 Whenever grasping a starter or part in a vise always use leather covered or copper covered vise jaws Take extra care with threaded parts or hou
72. sing Vent Lf Typical Installation with Engine Prelube System 4 Hose Starter Control Valve SMB 618 Oil Pressure Sensing Valve Exhaust XS 4 Hose Air Pressure IN Port JIC 37 Gage Adapter 1 4 NPT 4 Hose I y b JIC 37 Adapter Hd 1 1 2 NPT 1 1 2 Relay Valve SRV150 jg 1 1 2 Pipe To Prelube Pump JIC 37 Adapter 1 4 N PTT 1 1 2 Pipe 1 1 2 Pipe Tank maximum pressure not to exceed pressure rating on starter nameplate 4 Hose Standard System with Engine Prelube 1 1 2 Relay Valve SRV150 Dwg TPA843 2 OUT Port JIC 37 Adapter 1 4 N PT Ld For natural gas operation starter main exhaust must be piped away Bi To pipe the drive housing vent remove the drive housing plug and replace it with a suitable tubing line The tubing must vent at a safe location and must not be interconnected with any other exhaust lines which might introduce a back pressure on the drive housing vent Check Valve 150BMP 1054 Supply Typical Installation with Engine Prelube System when Supply Pressure is over Rated Starter Pressure 4 Hose P d Oil Pressure Sensing Valve
73. sings 4 Except for bearings always clean every part and wipe every part with a thin film of oil before installation 5 Check every bearing for roughness If an open bearing must be cleaned wash it thoroughly in a suitable cleaning solution and dry with a clean cloth Sealed or shielded bearings should never be cleaned Work grease thoroughly into every open bearing before installation 6 Apply a film of O Ring lubricant to all O Rings before final assembly Gear Case 1 Place the Drive Gear Bearing Retainer 59 over the rear end of the Drive Gear 2 Using an arbor press press the Rear Drive Gear Bearing 61 onto the rear end of the Drive Gear 3 Using retaining ring pliers install the Drive Gear Shaft Bearing Retainer 60 4 Position the Gear Case on a workbench Using a plastic hammer seat the Rear Drive Gear Bearing into the Gear Case by tapping the opposite end of the Drive Gear 5 Using retaining ring pliers and working through the access holes in the gear web install the Drive Gear Bearing Retainer 59 6 Lubricate the Drive Gear with approximately 8 oz 240 mL of Ingersoll Rand No 130 Grease Motor Housing 1 Clamp the Rotor in a vise threaded end up 2 Install the Rear Rotor Bearing 10 into the Rear End Plate 3 Using O Ring lubricant lubricate and install the Small Rear Rotor Bearing O Ring 10A onto the rotor shaft until it butts against the rotor shaft shoulder 4 Install the Rear End Plat
74. talled directly on the Starter or located remotely Although the Lubricator is capable of drawing lubricant from a source 4 ft 1 2 m lower than the point of installation Ingersoll Rand recommends installing the Lubricator as close as possible to the oil source We recommend using the unpressurized fuel return line as the source of lubricant However oil may be supplied from a separate receiver or the diesel fuel tank When the diesel fuel tank is the lubricant source install a 10 micron to 50 micron fuel filter in the oil supply line at the fuel tank The lubricant supply line should be fed into the fuel return line with the leg of the tee going to the lubricator directed in the down direction to insure that the lubricator does not draw air instead of oil LUBRICANT SUPPLY HOSE as O STARTER AIR SUPPLY OR OIL CHAMBER REMOTE INSTALLATION OF HDL2 LUBRICATOR 3 Install a 1 4 hose from the 1 8 NPTF oil inlet in the side of the HDL2 to the unpressurized fuel line diesel fuel tank or separate oil reservoir Tighten the fitting at the Lubricator to 15 to 36 ft lb 20 3 to 40 8 Nm torque The threads on the fitting must be clean assemble it without sealing compound or Teflon tape Connection must be vacuum tight NOTICE itial operation manually fill the oil supply line Before 4 Ifa separate lubrication reservoir is used fill it with diesel fuel
75. ting 12 Liberally grease the teeth on the ring gear with a good sticky gear grease or motorcycle chain lubricant This will help promote the life of the ring gear and the Starter Pinion 13 Place the Starter into position and mount it on the flywheel bell housing Tighten the mounting bolts to 100 ft Ib 136 Nm of torque 14 Install a 1 4 4 hose line from the DEL side of the Starter Control Valve to the IN port on the Starter Drive Housing 15 Install a 1 4 4 hose line from the OUT port on the Starter Drive Housing to the small pipe tapped port on top of the Starter Relay Valve 16 If the exhaust is not to be piped away install a No SS660 A674 Muffler or No SM450 A735 Road Splash Deflector in the exhaust port on the Motor Housing of the Starter 17 If the engine on which the Starter is mounted does not have a bell housing with a standard starter mounting and a bracket had to be manufactured for mounting we recommend that you add an additional support bracket at the motor end of the Starter here are four holes in the Motor Housing Cover for this purpose hey are tapped M10 1 50 to accommodate metric cap screws 18 Mount an HDL2 Lubricator on or near the Starter as shown in Dwg TPB978 on EN 4 19 Pressurize the complete starting system and check every connection with a soap bubble test There must be no leaks Barring Over the Engine Occasionally for setting injectors and or for timi
76. ton Return Spring Seat SS800 191 Models 330001394 58 Gear Case 55800 37 or SS815LB or 558251 558001 394 59 Drive Gear Bearing Retainer SS800 361 Models 60 Drive Gear Shaft Bearing Retainer 55800 632 22 Drive Pinion R Washer 55800 725 t61 Rear Drive Gear Bearing SS800 359 Drive Pinion L Washer 55800 725 1 62 Drive Gear 23 Drive Pinion for 55815108 or 558158 9 or SS815GB03R31 Models SS815R 13 31 SS815LB Models or SS815GB03L32 Models SS815L 13 32 for SS825RC or SS825C 9 or SS815GB03R91 and 558158 13 91 558251 Models SS825GCO03R91 Models Nameplate 55800 301 or SS815GB03L92 and 558151 13 92 Nameplate Screw 4 R4K 302 or SS825GC03R25 Models Relay Valve SRV150 or S5825GC03R25 Models SS825R 13 25 or SS825GC03L26 Models 55825L 13 26 Muffler SS660 A674 24 Pinion Spring Sleeve 55800 335 Road Splash Deflector SM450 A735 25 Pinion Spring Air Strainer SM450 A267AT or SS800RB SS815RB or Lubricator HDL2 SS825RC Models 39800319 In Line Lubricator NL 24 8 or SS800LB SS815LB or 558001 419 Tune up Kit includes illustrated parts SS825LC Models 6 2 7 8 10 10A 4 11 15 18 24 25 SS800 TK2 26 Drive Gear Screw SS800 179 27 31 33 34 36 37 39 50 51 60 and 61 1 27 Drive Gear Screw O Ring 55800 176 Not Illustrated t Indicates Tune up Kit part To keep downtime to a minimum it is desirable to have on hand certain repair parts We recommend that you stock one pair or set of each part indicated by
77. ts and Maintenance NOTICE The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards decreased motor performance and increased maintenance and may invalidate all warranties Ingersoll Rand is not responsible for customer modification of Starters for applications on which Ingersoll Rand was not consulted Repairs should be made only by authorized trained personnel Consult your nearest Ingersoll Rand Authorized Service center When the life of the Starters has expired it is recommended that the Starters be disassembled degreased and parts be separated by material so that they can be recycled Manuals can be downloaded from ingersollrandproducts com Refer all communications to the nearest Ingersoll Rand Office or Distributor 03531480 ed13 33 Notes Notes ingersollrandproducts com 02014 Ingersoll Rand dm Ingersoll Rand
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