Ingersoll-Rand 150T P Series Setup guide

Form P7520
04578001
Edition 3
May 2009
Save These Instructions
Turbine Powered Starter
Series 150T( )P
Installation and
Maintenance Information

2 04578001_ed3
Product Safety Information
Intended Use:
The 150T( )P Series 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 Product Safety Information Manual Form 45558624.
Manuals can be downloaded from www.irtools.com.
Lubrication
Ingersoll Rand No. 130 Grease80W90 Hypoid Gear Oil
WARNING
Do not grease excessively; too much grease may cause the
gearcase to overheat.
Operating Guideline
WARNING
When cranking attempts fail to start the engine in 30 seconds, stop and allow the starter to cool for 2-1/2 minutes before attempting
to start the engine.
Placing the Starter in Service
How to Order a Starter
Starter
Motor
Pre-Engaged
Gear Ratio
Drive Housing
Rotation
Pinion Code
Inlet
Exhaust
Orientation
Drive Housing
How to order a Starter
150T O
2
0
54-R
88
F
P
M
(Dwg. TP 2214)
Pinion Data
Pinion
Code
Number
of Teeth Blank DP/MOD
PD
PA Rotation
OD
inches mm inches mm
51 13 14 8/10 1.75 44.45 20° R/L 1.75 44.45
53 12 13 8/10 1.625 41.28 20° R/L 2.0 50.8
54 11 12 6/8 2 50.8 20° R/L 2.25 57.15
Other models available. Contact your Ingersoll Rand representative.

04578001_ed3 3
C
L3XØ (.660)
[(16.76)]
3XR (.640)
[(16.26)]
Ø(5.530)
[(140.46)]
4X R (2.675)
[(67.94)]
2X (120°)
Flange
Orientation
Hole
(2.455)
[(62.36)]
(17º 30')
3X (3.405)
[(86.49)]
Exhaust
C
L
(2.022)
[(51.36)]
4X R (.605)
[(15.37)]
2X (0º 30')
2X (60º)
Ø (5.750)
[(146.05)]
Inlet
(Dwg. TP1907)

4 04578001_ed3
Installation
Always make certain your Air Starter is properly installed. For
maximum performance, read this manual prior to the installation or
operation of Series 150T Turbine-Powered Starters.
General Information
1. It is strongly recommended 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. The starter is designed for either flange, or threaded pipe,
mounting at the inlet. The optional Flange Mounting Kit is
required for installation. All piping, hoses and valving must be
clean prior to installation. Make sure that the starter inlet remains
free of dirt and foreign material during installation.
3. In the actual mounting of a starter, it may be best 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:
regular ratchet wrench, sockets, universal joint, socket extension
and a single or double-end box wrench.
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, elbows, and the length of the
supply line, should be kept to a minimum. Use 1-1/4”hose or pipe
for supply lines up to 15 feet (4.6 m) long; uses 1-1/2”hose or pipe
if the supply line is over 15 feet (4.6 m) 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 repressurized 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. After all connections have
been made, check each joint with a soap bubble test. There
must be no leaks in live air lines. The slightest leak will cause the
system to lose pressure overnight. Always run the air supply line
from the side or top of the receiver, never at or near the bottom.
Moisture 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.
7. Whenever a hazardous gas is being used to operate the starter,
there must be no leaks in inlet or exhaust piping or from any
other starter joints. All discharges should be piped away to a
safe area.
8. Whenever possible, always mount the air starter so that the
exhaust port is pointed downward. This will help prevent any
accumulation of water in the starter motor.
9. We recommend installation of a “glad hand” for emergency
re-pressurizing of the system. To keep the“glad hand” clean
and free of dirt and to protect it from damage, a second“glad
hand” closed by a pipe plug can be mated to it, or a “glad hand”
protector bracket can be used.
10. It is recommended that a strainer be installed in the inlet line
for each starter. Ingersoll Rand offers 5 strainers: ST900-267-24
for 1-1/2”lines, ST900-267- 32 and ST900-267-32F for 2”lines,
ST900-267-48 for 3”lines and ST900-267-64 for 4”lines. These 300
mesh strainers provide 50-micron filtration and offer significant
protection against supply line contaminates which could damage
the turbine components. Replacement elements are ST900-266- 24
for 1-1/2”, ST900-266-32 for 2”pipe, ST-266-32F for 2”flange,
ST900-266-48 for 3”flange, and ST900-266-64 for 4”lines.
Orientation of the Starter
It is recommended that starters be ordered in the proper orientation
for your specic mounting requirements. However, if the starter must
be reoriented for installation, proceed as follows:
1. Refer to the dimension illustration on pages 2 and 3 and note
that the Drive Housing can be located in any one of eighteen
radial positions relative to the Gear Case. The exhaust port (Motor
Housing) 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.
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 nine
Drive Housing Cap Screws and rotate the Drive Housing to its
required position. Separation of the Drive Housing from the Gear
Case is not required. Reinstall the Drive Housing Cap Screws and
tighten to 100 in-lb (13 Nm) torque.
3. After the Drive Housing is properly oriented relative to the Gear
Case, determine if the inlet port will be favorably located for
hose installation. If either or both of these members must be
reoriented, use a 9/16”wrench to remove the four Motor Housing
Cover Cap Screws, and rotate the Motor Housing and/or Motor
Housing cover to the desired position.
NOTICE
Do not separate the Motor Housing from the Intermediate Gear
Case, as gear lubrication oil will be lost.
Reinstall the Motor Housing Cover Cap Screws and alternately
tighten them to 25 ft-lb (34 Nm) torque in 10 ft-lb (14 Nm)
increments.
Mounting the Starter
1. Study the appropriate piping diagrams on pages 7 and 8 and
install as indicated.
2. The air receiver tank for a starter installation must have a working
pressure rating equal to or greater than the maximum pressure at
which the starter will be operated.
3. When connecting the starter to a receiver tank that is already in
service, bleed off the air pressure in the tank prior to installing the
starter.
WARNING
Bleed o the air pressure through a valve or petcock. Do not
remove a plug from the tank while the tank is pressurized.
Drain off any water that may have accumulated in the bottom of
the tank.
4. Using a 1-1/4” short nipple, install the SRV125 Starter Relay Valve
on the end of the receiver tank as shown in the piping diagram.
NOTICE
Make certain the connectio n is made to the inlet side of the
Relay Valve indicated by the word“IN”; cast on the valve body.
5. For air installations, install the Starter Control Valve (SMB-618)
on the dash panel (for vehicular installations) or some other
appropriate panel (for stationary installations). An optional
control circuit, utilizing an electric solenoid control valve and
a panel mounted switch, is also available. Mount the 12V
Solenoid Valve (150BMP-1051B), or appropriate voltage solenoid,
securely and, preferably, in a vertical position away from any
concentration of heat, vibration or contamination. Connect the
leads to the operator’s starting switch, which should be located
on the dashboard or control panel.
6. Attach Starter Instruction Label (TA-STR-100) to control panel
adjacent to the Starter Control Valve.

04578001_ed3 5
7. Mount the Air Pressure Gauge (150BMP-1064) on or adjacent to
the control panel. It should be located where it is readily visible to
the operator.
8. Connect the Starter Control Valve to the Relay Valve with 1/4”
hose. Install a tee in this line with a short feeder hose to the
Pressure Gauge.
NOTICE
Make certain the hose is connected to the supply side (marked
“SUP”) of the Starter Control Valve.
9. To determine the exact length of 1/4” air hose required, run a
piece of heavy duty hose, or some other flexible tubing of the
same diameter, from the Relay Valve on the receiver to the starter
location on the engine.
10. Attach the 1/4” 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 feasible or practical
to attach the hose to the starter before or after the starter is
actually mounted. In some cases it may be necessary to attach
the hose to the starter before mounting.
12. If possible, liberally grease the teeth on the ring gear with a good
quality sticky gear grease. This will help promote the life of the
ring gear and the starter pinion.
13. Move the starter into position, and mount it on the flywheel
housing. Tighten the mounting bolts to 100 ft-lb (136 Nm) torque.
14. For Pre-Engaged Models, install a 1/4” hose line from the delivery
side (marked “DEL”) of the Starter Control Valve or Solenoid Valve
to the “IN” port on the Starter Drive Housing.
NOTICE
Inadvertent application of air pressure to the“OUT” port will
result in Drive malfunction (Pinion will fail to retract). If this
condition occurs, loosen Drive Housing Cap Screws (44) to vent
Gear Case (19). Also, loosen Housing Plugs (4) and (49) to vent
motor.
15. Install a 1/4” hose line from the “OUT” port on the Starter Drive
Housing to the small pipe tapped portion top of the Starter Relay
Valve or Solenoid Valve.
16. If the exhaust is to be piped away, attach appropriate piping to
the exhaust outlet on the motor housing.
17. Pressurize the complete starting system and check every
connection with a soap bubble test. There must be no leaks in
live air lines or other connections.

6 04578001_ed3
Mounting Dimensions
3XØ (1.250)
[(31.75)]
(1.750)
[(44.45)]
(5.750)
[(146.05)]
1/4-18 NPT Pressure Metering Port
Ø (5.750)
[(146.05)]
Ø (3.060)
[(77.72)]
2 - 11 1/2 NPT
Outlet
Optional Inlet Flange Adapter Kit IR P/N ST500-K166 (10590511)
(2.310)
[(58.67)]
(1.188)
[(30.18)]
1 1/4 - 11 1/2 NPT Inlet
4 Screws 7/16-14 UNC-3A Thd
Ø (5.750)
[(146.05)] Control Air in 1/4-18 NPT
(1.285)
[(32.64)]
(.840)
[(21.34)]
Control Out 1/4-18 NPT
(13.632)
[(346.25)]
(12.382)
[(314.50)]
(3.668)
[(93.18)]
(3.550)
[(90.17)]
3X (.440)
[(11.16)]
(4.000)
[(101.60)]
(.625)
[(15.88)]
[(23.83)]
(.938)
Ø (3.622)
[(92.00)]
(8.713)
[(221.31)]
(6.407)
[(162.74)]
(1.776)
[(45.12)]
Optional Exhaust Deector IR P/N ST500-A735 (10594885)
(1.017)
[(25.82)]
(4.510)
[(114.55)]
Travel
(Dwg. TP1908)

04578001_ed3 7
Installation
Typical Vehicular Installation
Starter Control Valve SMB-618 (Brass)

#4 Hose (1/4")
#4 Hose (1/4")
1 1/4" Hose
Inlet Flange Kit
ST500 - K166
1 1/4" N.P.T.
2" N.P.T. Exhaust Outlet
Exhaust Deector ST500 - A735

Use Sealant On All Pipe
Connections.
SMB - 441
NOTE:

On wet Clutch applications Use Control Ports located above center of Starter
Note:
Ingersoll Rand Part Number

1/4" N.P.T. pressure measuring Port. Operating pressure not to exceed max. pressure rating stamped on Starter Nameplate.
1 1/2" Pipe
Relay Valve 1 1/4" SRV125T

JIC 37° Adapter 1 1/4" N.P.T.
#4 Hose (1/4")
Air Pressure Gage 150BMP - 1064L

JIC 37° Adapter 1/4" N.P.T. SS350 - MC4


(2) Leads to Operators Starting Switch.
Solenoid Valve - 12 Volt 150BMP - 1051B

"Optional control circuit utilizing Electric Solenoid Control Valve and panel mounted Switch."
Air supply from Dry Air Brake Tank
Check Valve 150BMP - 1056

Air Receiver Tank
Drain Valve 1/2" N.P.T. 150BMP - 1067
(Dwg. TP909)

8 04578001_ed3
Installation (Continued)
High Pressure Supply
Relief Valve set at 15 P.S.I. above Regulator setting
Typical Stationary Installation
For Gas Operation, The Relief Valve Outlet must be piped away to a safe location
Pressure Regulator (Set Regulator so that the Open Valve Pressure, measured at the Starter Inlet, does not exceed the Maximum Operating Pressure listed on the Starter.) Standard High Pressure System Air or Gas. Use Pressure Regulator when Supply Pressure is over rating of Starter.
Ingersoll Rand Part Number



Note:
Use Sealant on all
Pipe Connections. Smb - 441
1/4" N.P.T. Pressure Measuring Port. Operating Pressure Not To exceed Max. Pressure rating stamped on Starter Nameplate.
Relay Valve 1 1/4" SRV 125
JIC 37° Adapter 1/4" N.P.T. SS350 - MC4




Air Pressure Gage 150BMP - 1064l (Air Only)
#4 Hose (1/4")
#4 Hose (1/4")
1 1/4" Hose
2" N.P.T. Exhaust Outlet **
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.
**
Inlet Flange Kit ST500 - K166
Starter Control Valve SMB - 618 (Brass / Air) SMBG - 618 (Chrome / Gas)
(Dwg. TP1910)

04578001_ed3 9
150T()P Turbine-Powered Starters Exploded Diagram
1, 2
43
46
5
7611
20
11
13
15
14
16
17 18
39
42
44, 45
43
41
40
38
36
37
37
35
34
32
31
33
30
27
26
25
24
23
22
21
19
48
7
29 28
47
49
12
8
(Dwg. TP1912)

10 04578001_ed3
150T()P Turbine-Powered Starters Parts List
Item Part Description Part Number Item Part Description Part Number
1 Cap Screw 107-25 27 Cover, Gear Case 150BMP-378X
2 Washer, Lock D02-504 28 O-ring 150BMP-604
3 Inlet Cover ST500-202 29 O-ring 150BMP-607
4 Plug HSPPS-2 30 Seal 150BMP-271
5 Gasket ST500-283 31 Collar 10BM-30
6 Motor Housing ST500-40 32 Shaft 150BMP-8-2
7 Pipe Plug - 1/8 NPT R2-227 33 Key 10BM-610
8Motor Assembly, RH 150TMFR-A53
(for 150TMP, RH rot)
34 Ring, Retaining 10BMP-606
35 Ring 10BMP-602
Motor Assembly, LH 150TMFL-A53
(for 150TMP, LH rot)
36 Bendix Drive - RH Index 101BMP-299-1
(for E88R54- Models)
Motor Assembly, RH 150TLFR-A53
(for 150TLP, RH rot) Bendix Drive - RH Index 101BMP-299-3 (for E88R53- Models)
Motor Assembly, LH 150TLFL-A53
(for 150TLP, LH rot)
37 Shift Ring 101BMP-705-1
38 Piston - O-ring Type 150BMP-703
11 O-ring SS800-152 39 Piston O-ring 150BMP-337
12 Gear Case Assembly 150TMF-A37 40 Spring, Return 101BMP-700-1
13 O-ring Y325-46 41 Drive Housing 150BMP-300-88
14 Gear Frame Assembly 150TMF-A108B 42 Bearing, Needle Roller ML50K-318
15 Bearing, Ball ST500-23 43 Pipe Plug HSPPS-2
16 Bearing, Ball ST500-105 44 Screw, Hex Cap 10BM-744
17 Pinion 150BME-17 45 Washer, Lock 10BM-67
18 Ring, Retaining ST500-69 46 Flange Kit - 1-1/4” Pipe ST500-K166
(Optional Equipment)
19 Gear Case 10BM-X37
20 O-ring Y325-29 47 Deector Assembly ST500-A735
(Optional Equipment)
21 Washer 10BM-25
22 Bearing, Needle 10BM-399 48 O-ring ST500-137
23 Washer 10BM-15 49 Plug, Magnetic Drain 150T-29
24 Drive Gear 150BME-9 * Muer 150T-312
(Optional Equipment)
25 Bearing T02-33
26 Gasket 150BMP-284
* Not Illustrated

04578001_ed3 11
Maintenance Section
WARNING
Always wear eye protection when operating or performing maintenance on this tool.
Always turn o the air supply and disconnect the air supply hose before installing, removing or adjusting any accessory on this tool or
before performing any maintenance on this tool.
Note: When reading the instructions, refer to exploded diagrams in parts Information Section (page no. 9 and 10) when applicable (see under
Related Documentation for form numbers).
Lubrication
Each time a Series 150T Starter is disassembled for maintenance or
repair, re-lubrication of key components is required. The following list
summarizes the lubricants required when performing maintenance
on the starter. Refer to the appropriate section for additional details
on the task you are attempting to perform.
For All Models
1. Lubricate all O-rings with O-ring lubricant before assembly.
2. Fill the intermediate gear case (12) with 55 ml (1.9 .oz.) of 80W90
gear oil. Do not overll.
3. Lubricate the rear motor bearing through the ll plug (7) with 7
ml (0.24 .oz.) of 80W90 hypoid gear oil. Do not overll.
4. Approximately 0.24 kg (8 .oz) of Ingersoll Rand No. 130 grease
is required to lubricate the gears in the oset gear case.
5. Drive housing and components are lubricated with
Ingersoll Rand No. 130 grease during assembly. See assembly
instructions for details.
Disassembly of the Starter
General Instructions
Always mark adjacent parts on the Inlet Cover (3), Motor Housing
(6), Gear Case (12), Oset Gear Case (19) and Drive Housing (41) so
these members can be located in the same relative position when
the Starter is reassembled.
Do not disassemble the starter any further than necessary to
replace a worn or damaged part.
Do not remove any part, which is a press t in or on a
subassembly unless the removal of that part is necessary for
replacement or repairs.
Always have a complete set of seals and O-rings on hand before
starting any overhaul of a 150T starter. Never reuse old seals or
gaskets.
When grasping a part in a vise, always use leathercovered or
copper-covered vise jaws to protect the surface of the part and
help prevent distortion. This is particularly true of threaded
members.
Do not remove any needle bearing from a press t unless you
have a new needle bearing on hand for installation. Needle
bearings are always damaged during the removal process.
Disassembly of the Housing Cover, Motor Assembly,
and Motor Housing
1. If replacing the Motor Assembly (8), remove two of the housing
Plugs (49) and drain the oil from the gearing before beginning
disassembly of the starter. Inspect the magnetized portion of the
housing Plug (49) for metal particles. Very ne metal particles are
normal. Remove particles and reinstall Plugs. Repeat for the other
two Plugs. Large particles or chips are an indication of a problem.
If found disassemble the Gear Case and inspect.
2. Using a 9/16” SAE box or open-end wrench, unscrew and remove
the four (4) Starter Assembly Cap Screws (1) and Washers (2).
3. Pull the Inlet Cover (3) from the Motor Housing (6).
4. Remove the drain plug from the rear motor bearing oil reservoir
and drain the oil.
5. Holding the Intermediate Gear Case (12), remove the motor
housing by tapping it on the exhaust outlet with a plastic
hammer or mallet. This operation is simplied if the Starter can
be positioned on a work bench vertically, resting on the engine
mounting ange.
6. Remove the Motor Assembly (8) by grasping the Motor Pinion
and pulling the Motor Assembly from the Motor Housing. If
diculty is encountered removing the motor assembly place
the motor and housing on a suitable support that will allow
the motor assembly to be dropped out of the housing. Insert
a suitable at-bottomed punch, approximately 3/16” diameter
through the oil ll port on the back of the motor housing. Lightly
1.
2.
3.
4.
5.
6.
tap the punch with a mallet to drive the Motor Assembly out
of the housing. It is important to maintain alignment of the
punch with the motor during this operation. It is also important
to protect the motor from dropping out of the housing
unexpectedly.
7. Remove the Intermediate Gear Case (12) by gently tapping it
around the circumference, with a plastic hammer or mallet,
upward to remove it from the Oset Gear Case.
8. In the event that the Planetary Gear Frame (14) is retained, by the
Oset Gear Housing, it must be removed separately. Position two
suitable pry bars on opposite side in between the Gear Frame
and the Oset Gear Case. Using equal pressure gently lift the
Gear Frame out of the Oset Gear Case. The pry bars may have
to be repositioned around the circumference several times to
complete the task.
Disassembly of the Oset Gear Case
1. Set the Gear Case and Drive Housing unit upright on the
workbench with the Drive Housing (41) upward.
2. Remove the Drive Housing Cap Screws (44) and lift o the Drive
Housing, Drive Gear and Starter Drive.
3. Thread a 5/16”-18 cap screw into the tapped hole in the Oset
Gear Case and drive the Bearing Ejecting Washer out. This will
drive the Drive Shaft Rear Bearing from the Oset Gear Case.
Disassembly of the Drive Housing
1. With the drive housing unit lying on the workbench, grasp the
Drive Gear (24) and pull the assembled Drive Shaft (32) from the
Starter Drive (36).
2. If the Drive Gear must be removed from the Drive Shaft, support
the Drive Gear on the table of an arbor press, and press the Drive
Shaft from the Drive Gear. Remove the Drive Gear Key (33).
3. Stand up the drive shaft assembly, bearing end up, in a sleeve
that contacts the Drive Shaft Collar (31), and press the Drive Shaft
from the bore of the Drive Shaft Front Bearing (25).
4. Position the Drive Housing (41) vertically, grasping the Oset
Gear Case Cover (27) in copper-covered vise jaws. Tap the
underside of the Drive Housing mounting ange with a soft
hammer to dislodge the Drive Housing from the Gear Case Cover.
Lift o the Drive Housing. The Piston Assembly and Starter Drive
will probably remain with the Drive Housing; make certain they
do not fall on the oor.
5. Do not remove the Drive Shaft Grease Seal (30) from the Oset
Gear Case unless it is absolutely necessary and you have a new
Seal on hand. The Seal is always destroyed in the removal process.
If the Seal must be removed, press it from the Gear Case Cover.
6. Withdraw the Piston (38) and Starter Drive (36) from the Drive
Housing. Withdraw the Piston Return Spring (40).

12 04578001_ed3
7. Remove the Shift Ring Retainer (34) and Shift Ring Spacer (35)
from the small bore of the Piston.
8. Slide the Piston forward toward the drive pinion until the two
halves of the Shift Ring (37) are free. Slide the Piston from the
Starter Drive.
9. Do not remove the Drive Housing Bearing (25) from the Drive
Housing unless you have a new bearing on hand. The bearing is
always destroyed in the removal process. If the bearing must be
removed, press it from the Drive Housing.
Cleaning the Parts
Once the Starter has been disassembled, clean all parts for
inspection.
1. Wipe all dirt, grease, etc. from the Starter Drive and sealed
bearings. Do not wash these parts in kerosene or other
solvent, as this will dilute and contaminate any sealed-in
lifetime lubricant.
2. Wash all parts except the Start Drive or any sealed bearing in
clean kerosene
Inspection of Parts
1. Discard all O-rings and gaskets. These should not be reused.
2. Check all grease seals. If these appear worn or distorted, remove
them from their parent member and discard. Discard any grease
seal that was removed during disassembly of the Starter.
3. Check all needle bearings. Discard any needle bearing that was
pressed from a parent member during disassembly of the Starter.
Remove and discard any other needle bearing that appears worn,
distorted, has loose needles or does not run freely.
4. Check all ball bearings. These should run freely without any rough
spots or binding. Discard any bearing that gives any indication of
wear.
Assembly
General Instructions
Always press on the inner ring of a ball-type bearing when
installing the bearing on a shaft.
Always press on the outer ring of a ball-type bearing when
pressing the bearing into a bearing recess.
Whenever grasping a starter or part in a vise, always use
leather-covered or copper-covered vise jaws. Take extra care with
threaded parts, shafts or housings.
Except for bearings, always clean every part and wipe every part
with a thin lm of oil before installation.
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.
Apply a lm of O-ring lubricant to all O-rings before nal
assembly.
Unless otherwise noted, always press on the stamped end of a
needle bearing when installing the needle bearing in a recess,
using a piloted arbor. The use of a at arbor, or installing the
bearing wrong end rst, may fracture the shell or lock the needles
against rotation.
Assembly of Drive Gear
1. If the Drive Shaft Grease Seal (30) was removed from the Gear
Case Cover (27), press in a new Seal so that the inner lips of the
Seal face the bearing recess for the Drive Shaft Front Bearing (25).
2. Apply a thin lm of moly-base grease to the Drive Shaft (32) and the
bore of the Drive Shaft Front Bearing and Drive Shaft Collar (31).
3. Press the Drive Shaft Collar, beveled end rst, onto the keyway
end of the Drive Shaft until it sets against the shoulder of the
splines.
4. Press the Drive Shaft Front Bearing onto the keyway end of the
Drive Shaft until it seats against the Drive Shaft Collar.
5. Install the Drive Gear Key (33) in the keyway on the Drive Shaft.
6. Press the Drive Gear (24), long hub rst, on the Drive Shaft until it
contacts the Drive Shaft Front Bearing.
Assembly of the Gear Case
1. Set the Gear Case (19) at on a table with the Drive Housing side,
the side with the twelve (12) hole pattern, facing upward.
2. Place the Bearing Ejecting Washer (21) in the bearing recess.
3. Press the Drive Shaft Rear Bearing (22), unstamped end rst, into
the bearing recess until the trailing face of the Bearing is ush
with the face of the bearing recess. Work some Ingersoll Rand
Bearing Grease No. 130 between the rollers of the bearing.
4. Wipe a thin lm of grease on the Drive Gear Thrust Washer (23),
and place the Washer on the lip of the bearing recess in the Gear
Case.
5. Apply about 0.24 kg (8 oz.) of Ingersoll Rand No. 130 Grease
to the assembled Drive Gear (24) and Drive Shaft (32), making
certain to work the grease between all the gear teeth, splines,
and bearing surfaces.
1.
2.
3.
4.
5.
6.
7.
6. Insert the assembled Drive Gear and Shaft, short hub end rst,
into the Gear Case so that the short hub enters the Drive Shaft
Rear Bearing.
7. Moisten the Gear Case Cover O-ring (29) and Piston O-ring (28)
with O-ring lubricant and install them in their respective grooves
on the Gear Case Cover (27).
8. Place Gasket (26) on gear case face.
9. Install the Gasket (26) on the Gear Case and slide the assembled
Gear Case Cover, bearing recess rst, down over the Drive Shaft
until it seats against the Gear Case.
Important: Check the inner lip of the Drive Shaft Grease Seal
to make certain that it did not fold outward toward the end of
the Drive Shaft. If it did fold outward, you must reinstall the
Gear Case Cover, using a ne pointed instrument to roll the
lip of the Seal in the proper direction.
Assembly of the Piston
1. Stand the Start Drive (36), pinion end down, on the workbench.
Place the Piston (38), large diameter rst, down over the Starter
Drive.
2. Place the two halves of the Shift Ring (37) in the wide channel at
the upper end of the Piston.
3. Slip the Shift Ring Spacer (35) against the Shift Ring, and install
the Shift Ring Retainer (34) in the groove in the piston boss.
4. Moisten the Piston O-ring (39) with O-ring lubricant, and install it
in the groove on the Piston.
Assembly of the Drive Housing
1. If the Drive Housing Bearing (42) was removed, stand the Drive
Housing (41) upright and press a new Drive Housing Bearing,
open end rst, into the Drive Housing until the closed end of the
Bearing is ush with the face of the Drive Housing. Work some
Ingersoll Rand Grease No. 130 in the Bearing.
2. Wipe a thin lm of Ingersoll Rand Bearing Grease No. 130 on the
bore of the Drive Housing.
3. Stand the Drive Housing on its small end, and insert the Return
Spring Seat, small bore rst, into the bore of the Drive Housing.
4. Set the Piston Return Spring (40) in the Drive Housing so that it
seats in the counterbore of the Return Spring.
5. Moisten the outside of the Piston with O-ring lubricant, and insert
the assembled Piston and Starter Drive, pinion end rst, into the
Drive Housing.
6. Apply a thin lm of Ingersoll Rand Bearing Grease No. 130 to the
surface of the Drive Shaft (32).
7. Carefully take the assembled Drive Housing and install it on the
assembled motor and Gear Case so that the Drive Shaft passes
through the Starter Drive and enters the bore of the Drive
Housing Bearing.
8. Orient the Drive Housing so that the punch mark made prior to
disassembly is aligned with the punch mark on the Gear Case.
9. Install the Drive Housing Cap Screws (44) and Lock Washers (45),
and tighten the Cap Screws to 100 in-lb (13 Nm) of Torque.

04578001_ed3 13
Test and Inspection Procedure
Assembly of the Intermediate Gear Case
1. Position the assembled Drive Housing and Gear Case on a table,
or xture, so that the open end of the Gear Case is oriented up,
and the pinion is down.
2. Lubricate the Gear Case O-rings (11, 13) with a thin lm of O-ring
lubricant and position them in the grooves in the bearing bore of
the Gear Case.
3. If required, press the Gear Frame Bearings (15,16) onto the Gear
Frame (14). The rear bearing (15) is usually pressed on rst. Take
care to press on the INNER race of these bearings when pressing
them on to the shaft.
4. Place the Oset Gear Pinion (17) onto the shaft of the Gear Frame
Assembly (14).
5. Install the Rotor Pinion Retainer (18) in the groove on the rotor
shaft taking care not to overexpand the ring while placing it on
the shaft. Make sure the Rotor Pinion Retainer is fully seated in
the groove before moving on to the next step.
6. Position the Gear Frame Assembly (14) by locating the outer race
of the small bearing in the bearing seat in the Oset Gear
Case (19). Care must be taken not to damage the O-ring in the
Oset Gear Case during this operation.
7. Lubricate the O-rings for the Intermediate Gear Case (11,13) with
O-ring Lubricant and install on the Intermediate Gear Case.
8. Set the Intermediate Gear Case on the Oset Gear Case making
certain the punch marks on both Gear Cases are aligned.
9. Install the Drain Plugs (49) in the Intermediate Gear Case.
10. Fill the Intermediate Gear Case, through the exposed open end,
with 55 ml (1.9 .oz.) of 80W90 gear oil. Do not overll.
Assembly of Motor Housing
1. Before installing the Motor Assembly (8), coat the O-rings on
the Motor Assembly and the inside of the Motor Housing bore
with O-ring lubricant. Position the Motor Housing with the main
bore opening in the vertical position. Carefully slide the Motor
Assembly down into the housing, with the geared shaft pointing
out. It is important to slide the Motor Assembly in as straight as
possibly to prevent a cut O-ring. When properly seated in the
Motor Housing the front exhaust passage, in the housing, should
be completely visible.
2. Set the Motor Housing assembly on the assembled Oset Gear
Case and Drive Housing assembly, making certain the punch
marks on the Intermediate Gear Case are aligned with those on
the Motor Housing Assembly.
3. Fill the uid reservoir at the back of the motor housing with 7
ml (0.24 .oz.) of 80W90 hypoid gear oil. Do not overll. Wrap
the ller plug with Teon tape and install in the motor housing.
Tighten to 5 to 10 ft-lb (6.8 to 13.6 Nm) of torque.
4. Wipe/clean the gasket surface on the rear of the Motor Housing.
Position the Motor Inlet Cover Gasket (5) on the Motor Housing.
5. Set Inlet Cover (3) onto the Motor Housing making certain the
punch marks on the Inlet Cover align with those on the Motor
Housing. Take care not to disturb the alignment of the Inlet Cover
Gasket when positioning the Inlet Cover.
6. Install the Motor Housing/Inlet Cover Cap Screws (1) and
Lockwashers (2). Tighten the Cap Screws to 25 ft-lbs (34 Nm) of
torque.
1. Clutch Ratcheting: Turn the Drive Pinion (36) 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 Pinion (36)
opposite the direction of Starter rotation. The Drive Pinion should
turn by hand.
3. Pinion Engagement: Apply 50 psig (3.4 bar) pressure air to
the engagement “IN” port. The Drive Pinion (36) should move
outward, and air should escape from the“OUT”port. Repeat
several times to insure proper operation. Plug the “OUT” port and
apply 150 psig (10.3 bar) to the “IN” port. Check and make sure no
air or gas is escaping.
4. Motor Action: Secure Starter in a vise and apply 90 psig (6.2 bar)
pressure using a 3/8”(9 mm) supply line to the inlet of the motor.
Starter should run smoothly, and in the direction stamped on the
nameplate. Chamfer on pinion teeth should be on trailing edge
of gear teeth.
5. Motor and Gear Case Seals: Plug the exhaust and slowly apply
20 psig (1.4 bar) pressure to the inlet of the motor. Immerse the
Starter for 30 seconds in a nonammable, bubble-producing
liquid. If the Starter is properly sealed, no bubbles will appear.
Parts 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 modication of motors 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 tool has expired, it is recommended that the tool be disassembled, degreased and parts be separated by material so that
they can be recycled.
Manuals can be downloaded from www.irtools.com
Refer all communications to the nearest Ingersoll Rand Oce or Distributor.

Notes:

Notes:

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