Ingersoll-Rand ST1000M Series Setup guide

47113766
Edition 2
March 2012
Save These Instructions
Turbine Powered Starters
Series ST1000M
Installation and Maintenance
Information

2 47113766_ed2
WARNING
Never exceed the nameplate operating pressure rating.
Always release the start button immediately after the engine
starts.
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.
•
•
•
NOTICE
If the engine has not started after 30 seconds of cranking, refer
to the engine maintenance guides for information on starting,
ignition, and fuel systems.
When using the starter for dynamic timing measurements, rest the
starter for 2½minutes between 30 second measurements.
An ST1000-267 strainer or equivalent 40 mesh strainer is
recommended to maximize the durability of the starter.
Supply must be free of contaminants. New piping must be free of
scale and welding slag.
The ST1000M series starter is designed for long crank heavy duty
applications. When cranking attempts fail to start the engine in 30
seconds, stop and allow the starter to cool for 2 ½ minutes before
attempting to start the engine.
Allow 30 seconds“wind down”time between any two successive
starting attempts.
•
•
•
•
•
•
Operating Guidelines
Placing Starter in Service
NOTICE
For maximum performance, read this manual prior to the
installation or operation of ST1000M series turbine-powered
starters. All parts references are for pre-engaged starters unless
otherwise noted.
General Installation Information
1. We recommend that on all vehicular installations and on
stationary engines subject to vibration that hoses of the specied
diameter be used instead of rigid pipe connections to the starter.
Engine vibration will loosen rigid pipe connections, whereas
hoses will absorb the vibration and connections will remain tight.
2. This starter is designed for ange mounting at the inlet. All
piping, hoses and valving must be clean prior to installation.
Make sure that the starter inlet is free of dirt and foreign material
during installation.
3. In mounting a starter, 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 requires mounting the starter 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 single or double-end box wrench.
5. Improper hook-up impairs the eciency of an air starter. 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. Keep the number of
tees and elbows and the length of the supply line to a minimum.
Use 1-½” hose or pipe for supply lines up to 15 feet long; use 2”
hose or pipe if the supply line is over 15 feet long.
6. We recommend that you install a strainer in the inlet line for each
starter. These 40 mesh strainers provide 420 micron ltration
and oer signicant protection against supply line contaminants
which could damage the turbine components. Ingersoll Rand
oers 2 sizes; ST1000-267-24 for 1½”lines and ST1000-267-32 for
2” lines. Replacement 40 mesh elements are: ST1000-266-24 for
1½” lines and ST1000-266-32 for 2”lines.
7. A leak in any live air line connections means that the system
will drain overnight and will have to be repressurized the next
morning by use of another vehicle or compressor.
Make connections bubble tight to avoid unnecessary costs
and delays. On all threaded connections throughout the system,
use Ingersoll Rand No. SMB-441 sealant or non-hardening
No.2 Permatex. 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.
8. Whenever using a hazardous gas to operate the starter, there
must be no leaks in inlet or exhaust piping or from any other
starter joints. Pipe away all discharges to a safe area.
Orientation of the Starter
We recommend that starters be ordered to proper orientation of
your specic mounting or installation requirements. However, if the
starter must be reoriented for installation, proceed as follows:
1. Refer to the orientation illustrations under“How to order a
starter”and note that the Drive Housing (79) can be located in
any one of sixteen radial positions relative to the Gear Case (49).
The air inlet can be located in any one of four radial positions
relative to the gear case. And the air inlet can be located in any
one of four radial positions relative to the drive housing.
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 (87) 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 28-30 lb-ft (38-41 Nm) of torque.
NOTICE
During eld orientation, do not change the relationship between
the oset gear case and the intermediate Gear Case (45). It is
important that the cut out section of the bearing boss on the
intermediate gear case aligns with the Drive Gear (54). See Dwg.
45548500 SH7 in “Intermediate Gear Housing – Assembly and
Installation”on page 17.
Product Safety Information
Intended Use:
The ST1000M 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 for Internal Combustion Engines Product Safety Information Manual Form 45558624.
Manuals can be downloaded from www.ingersollrandproducts.com

47113766_ed2 3
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, remove the four ”motor Housing Cover Cap Screws
(33) and rotate the Motor Housing (1) and/or Exhaust Housing
(16) to its desired position.
NOTICE
Do not separate the motor housing (1) from the intermediate
gear case (45) as gear lubrication oil will be lost.
4. Reinstall the starter assembly Cap Screws (33) and Lock Washers
(32) and alternately tighten them to 49-61 lb-ft (66-83 N-m) of
torque in 20 lb-ft (27 Nm) increments.
Mounting the Starter
1. Study the appropriate piping diagrams 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 o 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 still pressurized.
4. Drain o any water that may have accumulated in the bottom of
the tank.
5. Using a 1½” short nipple, install the starter relay valve SRV150 for
air applications SRV150SS for gas on the end of the receiver tank
as shown in the appropriate piping diagram.
NOTICE
Make certain the connection is made to the inlet side of the
starter relay valve indicated by the word“IN”, cast on the valve
body.
6. Install the starter control valve SMB-618 for air applications or
SMB-G618 for gas 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 are available. Mount the solenoid
valve 150-BMP-1051B (12V) or 150BMP-2451B (24V) 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.
7. Attach starter instruction label TA-STR-100 to the control panel
adjacent to the starter control valve.
8. Mount the 150 psi air pressure gauge 150 BMP-1064 on or
adjacent to the control panel. It should be located where it is
readily visible to the operator.
9. Connect the starter control valve to the starter relay valve with
¼” 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
“SUPP”) of the starter control valve.
10. To determine the exact length of 1½” air hose required, run a
piece of heavy duty hose or some other exible tubing of the
same diameter from the starter relay valve on the receiver to the
starter location on the engine.
11. Once the 1½” hose of correct length has been obtained, attach
the air hose to the outlet side of the starter relay valve and run
the hose through the frame, etc. to its nal position at the starter
location.
12. 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 many cases it may be necessary to attach the hose to
the starter before mounting.
13. 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.
14. Move the starter into position and mount it on the ywheel
housing. Tighten the mounting bolts to 100 lb-ft (136 N-m)
of torque or to engine manufacturer’s recommended torque
settings.
15. For Pre-Engaged Models only: Install a ¼”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.
16. Install a ¼” hose line from the “OUT” port on the starter drive
housing to the top of the starter relay valve or solenoid valve.
17. For straight exhaust models if the exhaust is to be piped away,
remove the standard Splash Deector (20), Spring (21), and
Splash Deector Screw (22) which are located at the rear of the
exhaust housing and replace the splash deector screw with a
¼” NPT pipe plug.
18. Pressurize the complete starting system and check every
connection with a soap bubble test. There must be no leaks in
the live air lines or other connections.
Barring over the Engine
Ingersoll Rand oers a line of pendant controlled barring motors for
safe and ecient barring of engines for use with reciprocating gas
engines up to 1000 liters (500 liters for diesel).
Visit www.ingersollrandproducts.com for more information on
Ingersoll Rand barring motors.

4 47113766_ed2
Performance Data
ST1060M B Ratio
Pressure
(psig)
Breakaway Torque
(lbf-ft)
Speed @ Max. Power
(rpm)
Max. Power
(hp)
Flow @ Max. Power
(scfm)
30 53 1175 7 370
60 115 1550 20 590
90 220 1780 39 820
120 295 1900 53 1050
150 353 2050 70 1290
ST1099M B Ratio
Pressure
(psig)
Breakaway Torque
(lbf-ft)
Speed @ Max. Power
(rpm)
Max. Power
(hp)
Flow @ Max. Power
(scfm)
30 82 1425 13 540
60 200 1850 36 890
90 347 2060 68 1240
ST1060M C Ratio
Pressure
(psig)
Breakaway Torque
(lbf-ft)
Speed @ Max. Power
(rpm)
Max. Power
(hp)
Flow @ Max. Power
(scfm)
30 62 1025 7 370
60 143 1350 20 590
90 256 1515 39 820
120 342 1675 53 1050
150 409 1780 70 1290
ST1099M C Ratio
Pressure
(psig)
Breakaway Torque
(lbf-ft)
Speed @ Max. Power
(rpm)
Max. Power
(hp)
Flow @ Max. Power
(scfm)
30 98 1225 13 540
60 234 1580 36 890
90 400 1770 68 1240

47113766_ed2 5
Mounting Dimensions
Pre-Engaged B & C Ratio : Elbow
Note:
1. For orientation information, see starter orientation
method section.
2. Starter weight: Approximately 73 lbs.
3. Apply pipe thread sealant (IR SMB-441 or equivalent)
on all pipe connections to prevent leaks.
4. *For natural gas operation, piped exhaust must be used
and drive housing vent plug removed. The drive housing
must be vented to a safe location not interconnected with
any other exhaust lines which may introduce a back pressure
in the drive housing.
Dual mm.
Dimension in.
156.00
6.142
1/4” N.P.T Pipe Plug in Housing Inlet Boss
can be removed and Gauge installed to
check supply pressure to starter.
Before re-installing Pipe Plug, clean
threads and apply Pipe Thread Sealant
(IR No. SMB-441) or equivalent
to prevent leakage.
172.01
6.772
R 86.00
3.386
1/4” N.P.T “I” (IN) Control Port for engaging pinion.
Operating Pressure : 30-150 psig (207-1034 kPa)
1/4” N.P.T “O” (OUT) Control Port for actuation of main
air supply to starter motor.
Operating pressure : 30-150 psig (207-1034 kPa)
596.87
23.499
596.68
22.428
226.02
8.898 292.86
11.530
222.50
8.760
R 76.00
2.992
23.00
0.906
105.50
4.154
159.50
6.280
58.37
2.298
50.80
2.000
85.73
3.375
28.50
1.122 146.00
5.748
16.70
0.657
92.00
3.622 Pilot Dia
SAE 03 Flange
18.50
0.728
136.53
5.375
136.50
5.374
Outline of Flange
with Spacer
2” NPT
6x5/16-18 UNC SHCS
98.43
3.875
123.83
4.875
Pinion Travel
* 1/8 NPT Drive Housing
Vent Plug
3X 120˚
Flywheel Face
Left Hand Rotation Right Hand Rotation
3X
(Dwg. 45660446)
Pre-Engaged B & C Ratio : Straight
1/4” N.P.T Pipe Plug in Housing Inlet Boss
can be removed and Gauge installed to
check supply pressure to starter.
Before re-installing Pipe Plug, clean
threads and apply Pipe Thread Sealant
(IR No. SMB-441) or equivalent
to prevent leakage.
172.57
6.794
R 86.00
3.386
1/4” NPT “I”(IN) Control Port for engaging pinion.
Operating Pressure : 30-150 psig (207-1034 kPa)
1/4” NPT “O”(OUT) Control Port for actuation of main
air supply to starter motor.
Operating pressure : 30-150 psig (207-1034 kPa)
58.37
2.298
50.80
2.000
85.73
3.375
28.50
1.122
92.00
3.622 Pilot Dia
Flywheel Face
159.50
6.280
18.50
0.728
136.53
5.375
Outline of Flange
with Spacer
2” NPT
6x5/16-18
UNC SHCS
98.43
3.875 134.21
5.284
439.13
17.289
4” NPT for Piped Exhaust
123.83
4.875
Left Hand Rotation Right Hand Rotation
209.17
8.235
518.02
20.395
To Splash Deector
During Operation
502.02
19.765
292.86
11.530
222.50
8.760
R 76.00
2.992
23.00
0.906
105.50
4.154
16.70
0.657
SAE 03
3X 120˚
146.00
5.748
3X
* 1/8 NPT Drive Housing
Vent Plug
Note:
1. For orientation information, see starter orientation
method section.
2. Starter weight: Approximately 73 lbs.
3. Apply pipe thread sealant (IR SMB-441 or equivalent)
on all pipe connections to prevent leaks.
4. *For natural gas operation, piped exhaust must be used
and drive housing vent plug removed. The drive housing
must be vented to a safe location not interconnected with
any other exhaust lines which may introduce a back pressure
in the drive housing.
(Dwg. 45663119)

6 47113766_ed2
Piping Diagrams
Typical Single Starter Installation, Pre-engaged.
Starter Solenoid Valve
150BMP-1051B (12V)
150BMP-2451B (24V)
Optional with use of
panel mounted switch.
Starter Control Valve
SMB-618 (Brass/Air)
SMBG-618 (Chrome/Gas)
#4 Hose (1/4”) #4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
2” Hose
#4 Hose (1/4”)
Oil Pressure Sensing Valve
Air Pressure Gauge
150BMP-1064L
(Air Only)
Strainer
ST1000-267
JIC 37° Adapter
1/4” N.P.T
SS350-MC4 JIC 37° Adapter
2” NPT X 1-1/2
NPT
JIC 37° Adapter 2”NPT
Inlet Flange
45640711 (As shown)
45640729 (w/ Spacer
* Drive Housing
Vent Plug
1/8” NPT
2X JIC 37°
Adapter 1/4”NPT
SS350-MC4
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 1/2” SRV150
Note:
1. Supply pressure must be adequate to maintain desired
operating pressure at the starter with strainer running and
not to exceed max. pressure shown on starter.
2. Apply pipe thread sealant (IR SMB-441 or equivalent)
on all pipe connections to prevent leaks.
3. *For natural gas operation, piped exhaust must be used
and drive housing vent plug removed. The drive housing
must be vented to a safe location not interconnected with
any other exhaust lines which may introduce a back pressure
in the drive housing.
(Dwg. 45660164 SH1)
Typical Multiple Starter Installation, Pre-engaged.
JIC 37° Adapter
2” NPT
JIC 37° Adapter
2” NPT
JIC 37° Adapter
2” NPT
Inlet Flange
45647011 (As shown)
45640729 (W/ Spacer)
Inlet Flange
45647011 (As shown)
45640729 (W/ Spacer)
Inlet Flange
45647011 (As shown)
45640729 (W/ Spacer)
JIC 37° Adapter
1½” N.P.T.
SS350-MC4
2X JIC 37° Adapter
¼” N.P.T. SS350-MC4
2X JIC 37° Adapter
¼” NPT SS350-MC4
2X JIC 37° Adapter
¼” NPT SS350-MC4
Starter Control Valve
SMB-618 (Brass/Air)
SMBG-618 (Chrome/Gas)
Starter Solenoid Valve
150BMP-1051B (12V)
150BMP-2451B (24V)
Optional with use
of panel mounted switch
#4 Hose (1/4”)
#4 Hose (1/4”)
Oil Pressure Sensing Valve
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
2” Hose
1½” Pipe
2” Hose
2” Hose
1½” Pipe
JIC 37° Adapter
1/4” N.P.T.
SS350 - MC4
JIC 37° Adapter
1/4” N.P.T.
SS350 - MC4
1/4” NPT pressure measuring
port. Operating pressure
not to exceed max.
pressure rating
stamped on starter
nameplate.
1/4” NPT pressure measuring
port. Operating pressure
not to exceed max.
pressure rating
stamped on starter
nameplate.
1/4” NPT pressure
measuring port.
Operating pressure
not to exceed max.
pressure rating
stamped on starter
nameplate.
*Drive Housing
Vent Plug
1/8” NPT
Relay Valve 1½”
SRV150
Air Pressure Guage
150BMP-1064L
(Air Only)
Strainer
ST1000-267
Relay Valve 1½”
SRV150
Relay Valve 1½”
SRV150
Strainer
ST1000-267
Strainer
ST1000-267
*Drive Housing
Vent Plug 1/8”N.P.T.
*Drive Housing
Vent Plug
1/8” NPT
Pipe Size
See Chart
No. of
Starters
2 2-1/2”
3-1/2”
3-1/2”
3-1/2”
3”
4”
4”
3”
3
4
5
ST1060M
150 PSIG
Min. Pipe Size
Supply must be adequate to maintain desired
operating pressures at the starters while
running. Pressure not to exceed max. pressure
shown on starter nameplate.
ST1099M
90 psig
Min. Pipe Size
Note:
1. Apply pipe thread sealant (IR SMB-441 or equivalent)
on all pipe connections to prevent leaks.
2. *For natural gas operation, piped exhaust must be used
and drive housing vent plug removed. The drive housing
must be vented to a safe location not interconnected with
any other exhaust lines which may introduce a back pressure
in the drive housing.
(Dwg. 45660164 SH3)

47113766_ed2 7
Standard High Pressure System when Supply Pressure is over Pressure Rating of Starter, Pre-Engaged.
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”)
#4 Hose (1/4”) #4 Hose (1/4”)
#4 Hose (1/4”)
To Prelube
Pump
Oil Pressure Sensing Valve
JIC 37° Adapter
1/4” NPT
SS350 - MC4
JIC 37° Adapter
2” NPT X 1½” NPT
Relay Valve 1½”
SRV150
Starter Solenoid Valve
150BMP-1051B (12V)
150BMP-2451B (24V)
Optional with use of panel mounted switch
2” Pipe
2” Hose
JIC 37° Adapter 2” NPT
Relay Valve
1½” SRV150
ST1000-267
Strainer
Set pressure regulator
to ensure pressure at
starter does not exceed
starter pressure rating
during operation.
High Pressure
Supply
Relief valve set at
15 PSI above regulator
setting
For gas operation, the relief
valve outlet must be piped
away to a safe location.
JIC 37° Adapter
1/4” N.P.T SS350-MC4
Air Pressure Gauge
150BMP-1064L
(Air Only)
2X JIC 37° Adapter 1/4”NPT SS350-MC4
* Drive Housing
Vent Plug 1/8”NPT
1/4” NPT pressure measuring
port. Operating pressure
not to exceed max.
pressure rating stamped
on starter nameplate.
Note:
1. Supply pressure must be adequate to maintain desired
operating pressure at the starter with strainer running and
not to exceed max. pressure shown on starter.
2. Apply pipe thread sealant (IR SMB-441 or equivalent)
on all pipe connections to prevent leaks.
3. *For natural gas operation, piped exhaust must be used
and drive housing vent plug removed. The drive housing
must be vented to a safe location not interconnected with
any other exhaust lines which may introduce a back pressure
in the drive housing.
Starter Control Valve
SMB-618 (Brass/Air)
SMBG-618
(Chrome/Gas)
Inlet Flange
45640711 (As shown)
45640729 (w/ Spacer
(Dwg. 45660164 SH2)
How to Order a Starter
Starter Family
Percent Arc Motor
Gear Set Ratio
Drvie/Motor Housing Type
Mounting Flange
Rotation
Drive Housing Orientation
Exhaust Orientation
Exhaust Type
Pinion
Inlet Orientation
Orientation Code
Drive Code
Percent Arc Motor*
60 : 60% Arc Motor
99 : 100% Arc Motor
B : 2.18 : 1
P : Pre Engaged
L : Left Hand
R : Right Hand
C : 2.53 : 1
D : 3.44 : 1
Gear Set Ratio
Drive Housing
Rotation
Pinion
See Pinion Selection Chart
Exhaust Type
Inlet Orientation
No Letter : Directional
S : Straight
0 to 3
Exhaust Orientation
Drive Housing Orientation
A to A-
If Exhaust Type is Directional : 0 to 3
If Exhaust Type is Straight: No Number
Model Number Coding
ST 10 99 M C 03 R 31 S 2 2 G -
(Dwg. 45662434 SH2)
* For available arc percentages, visit www.ingersollrandproducts.com or contact your nearest Ingersoll Rand distributor or Ingersoll Rand
Engine Starting Systems.
For dierent models or special applications, contact your nearest Ingersoll Rand distributor or Ingersoll Rand Engine Starting Systems at:
1-888-STARTAIR
1-888-78278247

8 47113766_ed2
Starter Orientation
Pre-Engaged Starter Orientation Method
Drive Housing Orientation
Reference Feature
Exhaust Orientation
Reference Feature
Inlet Orientation
Reference Feature
Drive Housing (A - A-)
Exhaust (0 - 3)
Inlet (0 - 3)
Orientation Shown : 22G -
(Dwg. 45662434 SH1)

47113766_ed2 9
Pinion Selection Table
Gear Set
Ratio Rotation # Teeth Outer Diameter (mm) Diametral Pitch Pressure Angle Pinion Code (from model number) Part Number
B or C Right 11 57.15 6/8 20° 25 SS825R-13-25
B or C Right 11 57.15 6/8 20° 25 SS825R-13SR-25*
B or C Right 12 57.15 6/8 20° 31 SS815R-13-31
B or C Right 14 62.00 3.5 MOD 15° 91 SS815R-13-91
B or C Right 14 65.61 6/8 20° 45 SS800R-13-45
B or C Right 14 58.50 3.5 MOD 20° 32 SS825R-13-932
B or C Right 15 69.85 6/8 20° 51 SS800R-13-51
B or C Right 15 70.60 4 MOD 14.5° 493 SS815R-13-493
B or C Left 11 57.15 6/8 20° 26 SS825L-13-26
B or C Left 11 57.15 6/8 20° 26 SS825L-13SR-26*
B or C Left 12 57.15 6/8 20° 32 SS815L-13-32
B or C Left 14 62.00 3.5 MOD 15° 92 SS815L-13-92
B or C Left 14 58.50 3.5 MOD 20° 42 SS825L-13-942
B or C Left 15 69.85 6/8 20° 52 SS800L-13-52
B or C Left 15 69.85 6/8 20° 52 SS825L-13-52
*Spark resistant pinions.

10 47113766_ed2
Construction - Pre-Engaged
ST1000M Turbine Starter (Pre-Engaged)
26
25
24
23
* Not pictured 4, 17, 32, 33.
16
13
18 8
5
19
6
11
10
93
88
89
40
39
41
90
50
52
53
54
62
61
63
64
55
65
78
59
60
71 73 72 69
79 75
76
77
81
85
84
83
82
81
70
74
67
68
66
51
28
16
7
20
21
22
12
15
14
11
27
1
31
14
13
29
30
38
35
36
36 44 34
45
46
42
43
47
48
49
56
58 86
87
57
37
2
(Dwg. 45660370 SH1)

47113766_ed2 11
ST1000M Turbine Starter (Pre-Engaged) - Exploded Diagram
85
84
83
82
81
79
78
77
76
75
74
72
73
71
70
87
86
80
26
25
24
23
33
32
16
22
21 20 16
17
17
33 32 5
18
19
6713 8
11
10
9
12 14
14 28 29
13 15 27
13 13
30 3
90
89
88 92
89
90
91
90
31
4
4
34
39
40
41
38
36
37
35
36
1
2
69
67
51
64
62
68
66
65
63
61
60
59
56
58
57
55
54
52
50
49
48
47
46
45
44
43
42
53
(Dwg. 45659794)

12 47113766_ed2
ST1000M Turbine Starter (Pre-Engaged) - Parts List
Item Part Description Part Number Item Part Description Part Number
--- Motor module 30 Rotor pinion
Right Hand Rotation, Straight Exhaust ST10_ _MR-37S* Right Hand Rotation ST1000L-17
Right Hand Rotation, Directional Exhaust ST10_ _MR-37D* Left Hand Rotation ST1000R-17
Left Hand Rotation, Straight Exhaust ST10_ _ML-37S* 31 O-ring SRV150-604
Left Hand Rotation, Directional Exhaust ST10_ _ML-37D* 32 Lock washer (4) SS800-26
--- Motor housing assembly ST1000M-A40 33 Screw (4) 45518586
1 Motor housing 45589322 --- Idler gear frame assembly ST1000-A108
2 Seal ST700-708 34 Idler gear frame ST900-108
3 Plug ROH-377 35 Idler gear (3) ST900-10
4 Magnetic plug (2) 150T-29 36 Idler gear bearing (6) ST400-24
** Nameplate ST1000-301 37 Idler gear bearing spacer (3) ST900-91
** Nameplate ST700-301 38 Idler gear shaft (3) ST900-191
** Nameplate screw (8) R4K-302 39 Gear frame bearing T06-24
5 Exhaust Housing O-ring Y327-163 40 Cap screw (3) R3F-7
6 Containment ring 45491057 --- Intermediate gear case assembly
7 Wave spring 45485174 B Ratio Gear Set ST900-A37
--- Motor assembly C Ratio Gear Set ST900-A37C
Right hand rotation ST10_ _R-37* 41 Ring gear 04324596
Left hand rotation ST10_ _L-37* 42 Seal ST700-272
8 Rotor 43 Bearing SS800-22
Right Hand Rotation ST1000R-53-37 44 Rear gear case o-ring Y327-162
Left Hand Rotation ST1000L-53-37 45 Intermediate gear case ST900-37
9 Nozzle housing 45491263 46 Front gear case o-ring Y327-163
10 Nozzle 47 Intermediate pinion
Right Hand Rotation ST1000R-19-_ _* B Ratio Gear Set SS800B-17
Left Hand Rotation ST1000L-19-_ _* C Ratio Gear Set SS825C-17
11 Screw (4) Y154-54 48 Intermediate pinion screw SS800-732
12 Wave spring 45480068 49 Intermediate gear case SS800-37
13 Bearing (2) ST1000-24 50 Drive gear shaft retaining ring SS800-632
14 Retaining ring 95223673 51 Front drive gear bearing SS800-278
15 Retaining collar 45514213 52 Rear drive gear bearing SS800-359
--- Exhaust housing kit 53 Drive gear bearing retaining ring SS800-361
Straight Exhaust ST1000K-562 54 Drive gear
Directional Exhaust ST1000K-350 B Ratio Gear Set SS815B-9
16 Exhaust housing C Ratio Gear Set SS825C-9
Straight Exhaust 45542339 55 Retaining ring SS800-181
Directional Exhaust 45542594 --- Bulkhead Kit SS800-K150
17 Pin Y178-37 56 Bulkhead SS800-150
18 Screen 45491032 57 Inner bulkhead o-ring SS800-151
19 Retaining ring 45491040 58 Outer bulkhead o-ring SS800-152
20 Splash deector --- Piston kit SS800-K703
Straight Exhaust ST700-735 59 O-ring SS800-337
Directional Exhaust N/A 60 Piston SS800-703
21 Deector return spring 42 Seal ST700-272
Straight Exhaust D10-275 61 Retaining ring SS800-366
Directional Exhaust N/A 62 Cup SS800-367
22 Deector return screw 63 Spring SS800-583
Straight Exhaust ST700-737 --- Clutch jaw kit
Directional Exhaust N/A Right Hand Rotation SS800R-K587
--- Exhaust ange kit Left Hand Rotation SS800L-K587
Straight Exhaust N/A 64 Jaw Clutch
Directional Exhaust ST700-K351 Right Hand Rotation SS800R-586
23 Exhaust adapter seal Y327-46 Left Hand Rotation SS800L-586
24 Exhaust ange ST700-351 65 Jaw
25 Lock washers (6) 845-58 Right Hand Rotation SS800R-585
26 Cap screws (6) ST700-703 Left Hand Rotation SS800L-585
27 Adapter 66 Drive gear screw O-Ring SS800-176
Right Hand Rotation ST1000R-212 67 Drive gear cup SS800-177
Left Hand Rotation ST1000L-212 68 Drive gear lock washer SS800-180
14 Retaining ring 95223673 69 Drive gear screw SS800-179
13 Bearing (2) ST1000-24 --- Drive shaft kit
28 Spacer 45478443 Right Hand Rotation SS800R-K8
29 Wave spring 45516911 Left Hand Rotation SS800L-K8

47113766_ed2 13
Item Part Description Part Number Item Part Description Part Number
70 Drive shaft 82 Pinion spring sleeve SS800-335
Right Hand Rotation SS800R-8 83 Drive pinion See“Drive Pinion
Left Hand Rotation SS800L-8 Selection Chart”
71 Rear drive shaft bearing SS800-399 84 Drive Pinion (R) Washer SS800-725
72 Drive shaft retainer SS800-209 Drive Pinion (L) Washer SS800-725-1
73 Large drive shaft bearing retaining ring SS800-107 85 Drive pinion screw
74 Piston return spring SS800-700 Right Hand Rotation SS800R-394
75 Piston return spring seat SS800-191 Left Hand Rotation SS800L-394
--- Drive housing kit SS825-K300 86 Drive housing lock washer (8) TE223A-415
76 Front drive shaft bearing SS800-363 87 Drive housing cap screw (8) SS800-744
77 Drive housing seal SS800-273 88 Screw (6) 45637162
78 Drive housing o-ring SS800-244 89 Inlet Flange 45619277
79 Drive housing 45628963 90 O-Ring 45619855
80 Drive housing vent plug P250-546 91 Flange Spacer 45626678
81 Pinion spring 92 Screw (6) 45640497
Right Hand Rotation SS800R-419
Left Hand Rotation SS800L-419
* Blanks are for motor arc percentage. Refer to the starter model code and the “How to Order a Starter” section for correct part selection.
** Not shown.
Description of Part Part Number
Seal Kit (includes items 2, 5, 23, 42, 44, 46, 57, 58, 59, 66, 77, 78) ST1000-SK1
Bearing Kit (includes items 71, 72 ) SS800-K399
Gear Kit (includes items 35, 36, 37, 38, 39, 41, 42, 43, 44, 46) ST1000-GK1
Inlet Flange Kit (includes items 88, 89, 90) 45640711
Inlet Flange Kit (includes items 89, 90, 91, 92) 45640729
Rotor Bearing Kit (includes items 7, 12, 13, 14, 15) ST1000-K24
Tune up Kit (includes items 52, 55, 57, 58, 59, 75, 78) ST700P-TK7
Right Hand Rotation Left Hand Rotation
Rotor replacement Kit (includes items 7, 8, 12, 13, 14, 15) ST1000R-K53-37 ST1000L-K53-37
Motor Adapter Kit (includes items 2, 13, 14, 27, 28, 29, 30) ST1000R-K212 ST1000L-K212

14 47113766_ed2
Maintenance, Disassembly / Assembly Instructions
WARNING
Always wear eye protection when operating or performing any maintenance on this starter. Always turn o the air or gas supply and
disconnect the air or gas supply hose before installing, removing or adjusting any accessory on this starter or before performing any
maintenance on this starter.
Lubrication
Each time an ST1000M series starter is disassembled for maintenance
or repair, lubricate the starter as follows:
For Models with Pre-Engaged Drive
1. Lubricate the inside diameter of the drive shaft (70) with
Ingersoll Rand No. 130 Grease.
2. Lubricate the pinion end of the drive shaft with Ingersoll Rand
No. 130 grease.
3. Wipe a thin lm of Ingersoll Rand No. 130 grease in the bore of
the drive housing (79).
4. Roll the piston return spring (74) in Ingersoll Rand No. 130
grease.
5. Coat the outside of the piston (60) with Ingersoll Rand No. 130
grease.
6. Lubricate the drive gear (54) with 8 oz. (240 ml) of Ingersoll Rand
No. 130 grease.
NOTICE
On models with inertia drive, do not lubricate the threaded area
of the drive shaft as it could collect dirt and foreign material
which will prevent ecient operation.
For all models (refer to “Lubrication and Torque Specications”)
1. Lubricate all O-Rings with O-Ring lubricant.
2. Add 5.4 oz (160 mL) of Dexron® II Automatic Transmission Fluid
through the side plug hole in the motor housing (1).
General Assembly and Disassembly Instructions
Always press on the bearing race or seal diameter that makes
contact with the wall of the bore or shaft in which the bearing is
being pressed in or on.
Whenever grasping the starter or any parts in a vise, use leather or
copper covered vise jaws and take extra care with threaded parts
and housings.
Excluding bearings, always clean every part and wipe each part
with a thin lm of oil before installing.
Clean all threads and ensure they are free of any foreign matter
before reusing.
Check every bearing for roughness. If an open bearing must be
cleaned, wash it thoroughly in a suitable clean 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 O-Ring lubricant to all O-Rings prior to assembly.
•
•
•
•
•
•
NOTICE
These steps outline the complete disassembly of each module
that makes up an ST1000 series starter. It is not always necessary
to completely disassemble the components listed in the
instructions. Only disassemble as far as necessary to perform the
appropriate maintenance or repairs.
Exhaust Housing
Removal and Disassembly
1. Secure the starter assembly in a vertical position with the exhaust
housing (16) oriented upwards.
2. If directional exhaust is used, make note of the orientation of the
exhaust housing. If orientation is lost, refer to the model number
and the appropriate orientation method instruction page in this
manual.
3. Remove the starter assembly cap screws (33) and lock washers
(32) from the starter assembly.
4. Rotate the exhaust housing approximately 45° and using a plastic
hammer, gently tap the exhaust housing ears to remove it from
the motor housing (1).
5. Remove the wave spring (7) from the exhaust housing.
6. Remove the exhaust housing O-Ring (5) from the exhaust
housing.
7. If necessary, remove the retaining ring (19) followed by the screen
(18).
8. For models with straight exhaust and if necessary, remove the
splash deector screw (22), deector return spring (21) and
splash deector (20).
Assembly and Installation
1. For models with straight exhaust, install the splash deector
(20) into the back of the exhaust housing (16). Coat the splash
deector screw (22) threads with Ingersoll Rand SMB-441
sealant and insert the screw along with the deector return
spring (21) into the splash deector bore. Tighten the splash
deector screw to 10-20 lb-ft (14-27 Nm) of torque.
2. Coat the exhaust housing O-Ring (5) with O-Ring lubricant and
install it into the exhaust housing.
3. If removed, insert the retaining ring (19) into the exhaust housing
to secure the screen.
4. Secure the assembled motor housing (1) in a vertical position
with the inlet port facing upward.
5. Lightly coat the wave spring (7) with O-Ring lubricant in order to
assist in holding the wave spring in place during assembly. Place
the wave spring in the appropriate bore in the exhaust housing.
6. Install the exhaust housing into the motor housing taking note of
the orientation for directional exhaust models.
7. With the motor housing installed onto the intermediate gear case
(45) and gear case (49), insert the starter assembly cap screws (33)
and lock washers (32) and tighten to 49-61 lb-ft (66- 83 Nm) of
torque in 20 lb-ft (27 Nm) increments.

47113766_ed2 15
Lubrication and Torque Specications
Directional Exhaust
Coat lightly with O-ring lubricant to secure in bore.
Notes:
1. Apply teon pipe sealant and torque all plugs to 7-14 Nm (5-10 lb-ft). 2. Coat all O-rings with O-ring lubricant.
3X Apply 243 Loctite® to threads torque to 7-8 Nm (60-70 lb-in)
3X Apply 243 Loctite® to threads torque to 14 Nm (10 lb-ft)
4X Torque to 66-83Nm (49-61lb-ft)
Apply light coat of Dow Corning Molykote G-N to entire lenght of Motor Housing bore and Splines of Rotor. Straight exhaust with B or C
Gear set ratio Drive Housing
Apply 160 mL (5.4 oz) Dexron I I ATF
Apply 243 Loctite® to threads torque to 122-129 Nm (90-95 lb-ft)
Torque to 38-41 Nm (28-30 lb-ft)
8X Torque to 38-41 Nm (28-30 lb-ft)
6X Torque to 31-38 Nm (23-28 lb-ft)
Torque to 98-119 Nm (72-88 lb-ft)
Coat splines with IR #130 grease
Coat bore with IR #130 grease
Coat Clutches and Splines with IR #130 grease
Pack with IR #130 grease 225-250 ml (7.6-8.5 oz)
Apply 243 Loctite® to threads torque to 14-27Nm (10-20lb-ft)
Coat lightly with O-ring lubricant to secure in bore.
Coat pinion with IR #130 grease
(Dwg. 45660370 SH2)

16 47113766_ed2
Motor Module
Removal and Disassembly
1. Remove both magnetic plugs (4) and drain the uid from the
motor housing (1).
2. After drained, secure the starter assembly vertically and reinstall
one of the magnetic plugs.
3. If necessary, remove the exhaust housing. See “Exhaust Housing
- Removal and Disassembly”.
4. Slowly apply air to the location of the absent magnetic plug using
a blow gun to separate the motor housing from the intermediate
gear case (45). Remove the motor housing.
5. Using the ST1000 motor removal tool ST1000-TLK1, remove the
containment ring (6) followed by the nozzle housing (9) and
motor assembly from the motor housing. Take extra caution to
not damage the rotor blades or grab them with unprotected
hands as they are delicate and can be very sharp.
6. Remove the cap screws (40) from the idler gear frame (34) and
remove the idler gear frame from the motor housing. For idler
gear assembly and disassembly instructions, see the
“Idler Gear Set” section.
7. Secure the motor housing in a vise while maintaining easy access
to the adapter (27) and rotor pinion (30).
NOTICE
The direction of the rotor pinion and adapter threads can
be read from the face of the rotor pinion. If“ST1000R-17” is
stamped on the face of the rotor pinion, the rotor pinion and
adapter have right hand threads. Likewise if“ST1000L-17” is
stamped on the face of the rotor pinion, the rotor pinion and
adapter have left hand threads. Left hand rotation starters have
right hand threads whereas right hand rotation starters have left
hand threads.
8. Using the rotor pinion and adapter tools ST1000-TL2 and
ST1000-TL1, separate the rotor pinion from the adapter.
9. Remove the rotor pinion.
10. From the motor housing, remove the retaining ring (14) which
secures the adapter (27).
11. Remove the adapter by pushing from the threaded end.
12. Remove the wave spring (12), inlet plug (3), and the remaining
magnet plug from the motor housing.
13. Remove the O-Ring (31) from the motor housing and if necessary
pull the seal (2) from the motor housing. The seal is not
re-useable if removed.
14. If necessary, press the two bearings (13) and spacer (28) from the
adapter.
Assembly and Installation
1. Press the seal (2) into the motor housing taking care to not
damage the seal surfaces.
2. Using the punch ST1000-TL3, press one bearing (13) onto the
adapter (27), slide the spacer (28) over the adapter, then press the
other bearing (13) onto the adapter.
3. Place the wave spring (29) into the motor housing (1) bore.
4. Slide the adapter threaded end rst into the motor housing bore.
5. Compress the wave spring by pushing the adapter down and
insert the retaining ring (14) into the motor housing.
6. Secure the motor housing in a vice with easy access to both ends
of the adapter.
7. Apply 243 Loctite® to the adapter threads.
8. Thread the rotor pinion (30) onto the adapter. Using the rotor
pinion and adapter tools ST1000- TL2 and ST1000-TL1 tighten the
rotor pinion to 40-45 lb-ft (54-61 Nm) of torque.
NOTICE
The direction of the rotor pinion and adapter threads can
be read from the face of the rotor pinion. If“ST1000R-17” is
stamped on the face of the rotor pinion, the rotor pinion and
adapter have right hand threads. Likewise if“ST1000L-17” is
stamped on the face of the rotor pinion, the rotor pinion and
adapter have left hand threads. Left hand rotation starters have
right hand threads whereas right hand rotation starters have left
hand threads.
9. Install the inlet pipe plug (3) into the motor housing along with
each magnetic plug (4). Coat all threads with Ingersoll Rand
SMB-441 sealant. Tighten to 7-14 Nm (5-10 lb-ft) of torque.
10. Coat the O-Ring (31) with O-Ring lubricant and install it into the
motor housing.
11. Install the idler gear set assembly by placing it over the rotor
pinion. Coat the threads of the three cap screws (40) with 243
Loctite® and secure the idler gear assembly to the motor housing.
Tighten the cap screws to 14 Nm (10 lb-ft) of torque.
12. Lightly coat the inside diameter of the motor housing bore
in which the motor assembly, containment ring, and exhaust
housing are installed as well as the splines of the rotor (8) with
Dow Corning Molykote® G-N Metal Assembly Paste.
13. Slide the motor assembly into the motor housing. Rotate the
rotor to assist in meshing with the adapter.
14. Slide the containment ring (6) into the motor housing.
15. Coat the rear gear case O-Ring (44) with O-Ring lubricant and
place the motor housing onto the intermediate gear case (49)
allowing the rotor pinion to mesh with the idler gears (35).
16. Align the assembled exhaust housing (16) See “Exhaust housing
assembly” with the motor housing in the desired orientation.
17. Install the starter assembly cap screws (33) and lock washers (32)
and tighten to 49-61 lb-ft (66-83 Nm) of torque in 20 lb-ft (27 Nm)
increments.
18. Remove one of the magnetic plugs (4) and add 5.4 oz (160 mL) of
Dexron® II Automatic Transmission Fluid to the motor housing.
19. Coat the threads with SMB-441 and reinstall the magnetic plug.
Tighten to 7-14 Nm (5-10 lb-ft) of torque.
Removal and Disassembly
1. Remove the motor assembly from the motor housing. Refer
to steps 3-5 in the“Motor Module - Removal and Disassembly”
section.
2. With the motor assembly removed from the motor housing, press
the rotor (8) and bearing (13) opposite the splined shaft from
the nozzle housing (9). The retaining collar (15) will also become
loose from the splined end of the rotor.
3. If necessary, remove the press t bearing (13) from the rear of the
rotor.
4. Remove the retaining ring (14) from the nozzle housing followed
by the bearing (13) and wave spring (12).
5. Remove the nozzle cap screws (11) from the nozzle housing and
remove the nozzle (10).
Assembly and Installation
1. Apply 243 Loctite® to the nozzle cap screws (11) and fasten the
nozzle (10) to the nozzle housing (9). Orient the nozzle so that the
counterbores of the screw holes face outward. Tighten the cap
screws to 60-70 lb-in (7-8 Nm) of torque.
2. Using the rotor tool ST1000-TL4, press the rear bearing (13) onto
the rotor (8) boss opposite the splined end.
3. Place the nozzle and nozzle housing assembly over the rotor with
the nozzle housing upward.
4. Place the wave spring (12) over the splined end of the rotor.
5. Press the front bearing (13) onto the rotor.
6. Insert the retaining ring (14) into the nozzle housing to secure the
front bearing.
7. Press the retaining collar (15) onto the splined end of the rotor.
8. Coat the splines of the rotor with Dow Corning Molykote® G-N
metal assembly paste.
9. See steps 12-18 in “Motor Module - Assembly and Installation”.
Motor Assembly

47113766_ed2 17
Intermediate Gear Case
Removal and Disassembly
1. Remove the motor housing (1) from the intermediate gear case
(45) and the idler gear set from the motor housing. See
“Motor housing removal and disassembly.”
2. With the idler gear set removed from the motor housing, press
the gear frame bearing (39) o of the shaft of the idler gear frame
(34).
3. Press the idler gear shafts (38) out of the gear frame and remove
the idler gears (35).
4. Press one of the idler gear bearings (36) out of the idler gear,
remove the spacer (37), and press out the other idler gear
bearing. Repeat this process for the other two idler gears.
Assembly and Installation
1. Press one idler gear bearing (36) into an idler gear (35) followed
by an idler gear spacer (37) and another idler gear bearing.
Repeat for the remaining two idler gears.
2. Insert the assembled idler gear into the idler gear frame (34)
and align the gear with one of the holes in the idler gear frame.
Press an idler gear shaft (38) into the gear frame and idler gear
assembly. Repeat for the remaining two idler gear assemblies.
3. Press the gear frame bearing (39) onto the idler gear frame.
4. Place the idler gear set assembly over the rotor pinion in the
motor housing and secure it using the three cap screws (40).
Coat the threads of the screws with 243 Loctite® and tighten to 14
Nm (10 lb-ft) of torque.
Removal and Disassembly
1. Remove the motor housing (1) from the intermediate gear case
(45). See steps 1-4 “Motor Module-Removal and Disassembly”.
2. Separate the intermediate gear case assembly from the gear case
(49).
3. Support the intermediate gear case assembly on a bench and
position it in a copper-faced vise so that the intermediate pinion
(47) is secured in the jaws of the vise. Tighten the vise only
enough to hold the intermediate pinion securely.
WARNING
If the intermediate gear case is not supported on a bench and if
the intermediate pinion retaining screw is completely removed,
the intermediate gear case and components could fall causing
injury.
4. Loosen the intermediate pinion retaining screw (48) 1.5 turns. Do
not remove.
5. Remove the intermediate gear case assembly from the vise and
remove the intermediate pinion. Remove the rear gear case
O-Ring (44) and front gear case O-Ring (46) from the intermediate
gear case (45).
6. Remove the ring gear (41) and seal (42).
7. Remove the bearing (43) by pressing from the front of the
intermediate gear case.
Assembly and Installation
1. Press the bearing (43) followed by the seal (42) with at side
against the bearing into the intermediate gear case (45).
NOTICE
Make sure that the at side of the seal is installed against the
bearing.
2. Position the intermediate gear case over the gear frame (41) and
slide it onto the notched shaft.
3. Place the intermediate pinion (47) into the intermediate gear case
and rotate until the notches of the pinion and gear frame mesh.
4. Apply 243 Loctite® to the threads of the intermediate pinion
screw (48) approximately 3 mm from the end of the screw and
tighten the screw hand tight.
5. Support the intermediate gear case assembly on a bench and
position it in a copper-faced vise so that the intermediate pinion
is secured in the jaws of the vise. Tighten the vise only enough to
hold the intermediate pinion securely.
6. Tighten the intermediate pinion screw to 90 lb-ft (122 Nm) of
torque.
7. Lubricate the rear gear case O-Ring (44) and front gear case
O-Ring (46) and install them on the intermediate gear case. The
front gear case O-Ring is installed on the intermediate gear case
side with the pinion on it.
8. Pack the intermediate pinion (47) with 225-250 mL (7.6-8.5 oz)
Ingersoll Rand No. 130 grease.
9. Place the intermediate gear case assembly with intermediate
pinion end rst into the gear case assembly in such a way that
the notch in the intermediate gear case faces the drive gear (54)
located in the gear case. See Dwg. 45548500 SH7.
Notch oriented such that
intermediate pinion and
drive gear may mesh fully.
(Dwg. 45548500 SH7)
NOTICE
Failure to align the intermediate gear case notch and drive gear
will result in damage to the starter and if attempted to put into
service will require disassembly and repair.
Idler Gear Set

18 47113766_ed2
Drive Housing (Pre-Engaged)
Removal and Disassembly
1. Mark the orientation between the gear case (49) and drive
housing (79). If orientation is lost, refer to the model number
and the appropriate orientation method instruction page in this
manual.
2. Support the starter assembly on a bench and position it in a
copper-faced vise so that the drive pinion (83) is secured in the
jaws of the vise. Tighten the vise only enough to hold the pinion
securely.
3. Remove the drive pinion screw (85), drive pinion washer (84),
drive pinion (83), pinion spring sleeve (82), and pinion spring (81).
NOTICE
Left hand rotation starters have drive pinion screws with right
hand threads. Right hand rotation starters have drive pinion
screws with left hand threads. See“How to Order a Starter” if
rotation is unknown.
4. Using a 5/16” (8 mm) x 8”(203 mm) long hex inserted through the
threaded hole of the drive shaft, remove the drive gear screw (69)
from the drive gear (54).
5. Separate the drive housing from the gear case by removing the
drive housing cap screws (87) and lock washers (86).
WARNING
Failure to adhere to the following procedure could result in
injury to personnel.
6. Place the drive housing in a press with the piston (60) end up.
Apply a load to the piston in order to compress the piston return
spring (74). While the spring is compressed, remove the bulkhead
retainer (55). Do not use compressed air to load the piston in
order to remove the bulkhead retainer.
CAUTION
Make sure the tension of the spring pushes the bulkhead out of
the drive housing before removing the drive housing from the
arbor press.
7. Remove the bulkhead (56) from the piston.
8. Remove the outer bulkhead O-Ring (58) and inner bulkhead
O-Ring (57).
9. Remove the drive shaft (70) from the drive housing.
10. Remove the piston return spring and the piston return spring
seat (75) (for B and C ratio drive models only).
11. Remove the piston O-Ring (59) from the piston.
12. Compress the clutch spring (63) by pressing the clutch spring cup
(62) and remove the clutch spring cup retainer (61).
13. Remove the clutch spring cup, clutch spring, and both clutch jaws
(64) (65) from the drive shaft.
14. Remove the front drive gear bearing (51), drive gear cup (67),
drive gear lock washer (68), drive gear screw O-Ring (66), and
drive gear screw (69) from the inside of the drive shaft.
15. Press the drive shaft along with the drive shaft bearing (71) and
drive shaft retainer (72). If drive shaft bearing replacement is
necessary, use a small chisel to cut and remove the drive shaft
retainer and press the drive shaft bearing o of the drive shaft.
16. Press the front drive shaft bearing (76) from the drive housing
and pull the drive housing seal (77) from the drive housing.
Only remove each part if replacement is necessary as they are
damaged upon disassembly.
Assembly and Installation
1. Press the drive housing seal (77) into the drive housing (79) so
that the lip of the seal faces the exterior of the drive housing
followed by the front drive shaft bearing (76).
2. For B and C drive gear ratio models, insert the piston return
spring seat (75) so that the at edge rests against the front drive
shaft bearing.
3. Press the rear drive shaft bearing (71) onto the drive shaft (70).
4 Slide the rear bearing retainer (72) convex side rst onto the drive
shaft. Press it into position according to the instructions
(SS800-110) included with the new retainer.
5. Gather the drive gear screw O-Ring (66), drive gear cup (67), drive
gear lock washer (68), and drive gear screw (69) and assemble
such that the drive gear screw head rests inside the drive gear
cup.
6. Secure the drive shaft in a vise with externally splined end
downwards.
7. Insert the drive gear screw assembly into the drive shaft with
screw head facing downwards.
8. Lubricate the inside diameter of the drive shaft with
Ingersoll Rand No. 130 lubricant.
9. Insert the drive gear bearing (51) into the drive shaft.
10. Lubricate the driven clutch jaw (64) and driving clutch jaw (65)
with Ingersoll Rand No. 130 lubricant. Install the driving clutch
jaw into the drive shaft with jaw teeth facing upwards. Install the
driven clutch jaw into the drive shaft with the jaw teeth facing
downwards.
11. Place the clutch spring (63) into the drive shaft on top of the
driven clutch jaw.
12. Place the clutch spring cup (62) on the clutch spring.
13. Press the clutch spring cup down and install the clutch spring cup
retaining clip (61) into the drive shaft.
NOTICE
If it is necessary to replace the drive housing and drive
components, make sure that the piston seal (SS800-272) has
been removed from the rear of the new piston (60). The piston
seal must be removed to prevent pressure build-up which will
cause movement of the planet gear frame shaft seal (42). If
this condition occurs, the piston cannot retract and the drive
pinion (83) will remain in engagement with the ywheel causing
damage to the starter drive train and/or starter motor. To
remove the piston seal, insert a screwdriver inside the lip of the
seal and pry it loose from the piston.
14. Lubricate the piston O-Ring (59) with O-Ring lubricant and install
it in the groove on the piston 60).
15. Install the piston onto the drive shaft until it seats against the rear
drive shaft bearing.
16. Install the large drive shaft bearing retaining ring (73) into the
interior of the piston.
17. Remove the drive shaft from the vise and slide the piston return
spring (74) over the drive shaft. Snap the end coil of the spring
into the piston so that it rests on the large drive shaft bearing
retaining ring.
18. Lubricate the assembled drive shaft and insert it into the drive
housing.
19. Lubricate the outer bulkhead O-Ring (56) and inner bulkhead
O-Ring (57) and install each onto the bulkhead (58).
20. Slide the bulkhead over the piston and into the drive housing.
21. Place the drive housing assembly in a press and press the piston
down.
NOTICE
Feel the underside of the drive housing to make sure the drive
shaft passes through the bearing.
22. Install the bulkhead retaining ring (55) into the drive housing.
WARNING
Make sure the bulkhead retainer is properly seated in the drive
housing groove before easing o the arbor press. Failure to
do so will allow improperly retained parts to separate when
removed from the arbor press resulting in injury to personnel.

47113766_ed2 19
Drive Housing (Inertia)
Removal and Disassembly
1. Mark the orientation between the gear case (49) and drive
housing (59). If orientation is lost, refer to the model number
and the appropriate orientation method instruction page in this
manual.
2. Remove the drive housing cap screws (62) and lock washers (61).
3. Tap the drive housing with a plastic hammer to help dislodge it
from the gear case cover (56).
4. Place the drive housing in an arbor press with the bearing end up.
Press the drive housing bearing (60) from the drive housing.
5. Displace the locking spring on the starter drive (58) and remove
the screw securing it to the drive gear (51) shaft and slide the
starter drive o of the drive gear shaft.
6. Remove the two drive gear keys (52) from the drive gear shaft.
7. Remove the gear case cover from the gear case.
8. Remove the drive housing O-Ring (57) and gear case cover O-
Ring (55) from the gear case cover.
9. Remove the drive gear from the gear case.
10. Remove the rear drive gear bearing (50), drive gear shaft seal (54)
and front drive gear bearing (53) from the drive gear.
Assembly and Installation
1. Install the rear drive gear bearing (50) onto the shorter drive gear
(51) shaft.
2. Install the front drive gear bearing (53) onto the longer drive gear
shaft.
3. Install the two drive gear keys (52) into the key slots in the drive
gear shaft.
4. Press the drive gear shaft seal (54) onto the longer drive gear
shaft with the lip facing upward.
5. Lubricate the drive gear with approximately 8 oz. (240mL) of
Ingersoll Rand No. 130 grease.
6. Slide the drive gear into the gear case (49) seating the rear drive
gear bearing into the corresponding bore in the gear case.
7. Lubricate with O-Ring lubricant and install the gear case cover
O-Ring (55) in the groove on the gear case cover.
8. Lubricate with O-Ring lubricant and place the drive housing
O-Ring (57) on the lip of the gear case cover located opposite the
side which encases the front drive gear bearing.
9. Install the gear case cover onto the gear case.
10. Slide the starter drive (58) onto the drive gear shaft. Tighten the
starter drive locating the ring and screw securely.
11. Press the drive housing bearing (60) into the drive housing (59)
and lubricate it with Ingersoll Rand No. 130 grease.
See Dwg. TPD786 for recommended needle bearing punch size.
Needle Bearing inserting Tool
Shoulder to
Regulate Depth
Pilot to t I.D. of Bearing.
Length of Pilot to be
approximately 1/8” less than
length of Bearing
15°
(Dwg. TPD786)
12. Install the drive housing onto the gear case cover. Make sure the
orientation is the same as initially marked.
13. Install the drive housing cap screws (62) and lock washers (61)
and torque to 28 lb-ft (38 Nm) of torque.
Gear Case
Removal and Disassembly
1. Separate the motor housing and intermediate gear case (45) from
the gear case (49). See steps 1-2 in “Intermediate Gear Housing
- Removal and Disassembly.”
2. Remove the drive housing assembly from the gear case (49).
See steps 1-5 in “Drive Housing pre-engaged) - Removal and
Disassembly” for pre-engaged starters and steps 1-3 in “Drive
Housing (inertia) - Removal and Disassembly”for inertia starters.
3. Remove the drive gear bearing retaining ring (53). Rotate the
drive gear until the retaining ring can be accessed through the
access holes in the drive gear web.
4. Remove the drive gear from the gear case.
NOTICE
Do not disassemble the drive gear (54) and clutch parts. If the
drive gear shaft is defective, install a new or factory-rebuilt unit.
5. Remove the drive gear shaft retaining ring (50) and the rear drive
gear bearing (52) from the drive gear.
Assembly and Installation
1. Slide the rear drive gear bearing retaining ring (53) over the short
shaft of the drive gear.
2. Press the rear drive gear bearing (52) onto the short shaft of the
drive gear.
3. Install the drive gear shaft retaining ring (50) to secure the rear
drive gear bearing.
4. Insert the drive gear into the gear case (49) aligning the rear drive
gear bearing with the appropriate bore in the gear case. Seat
the bearing against the gear case using a plastic hammer to tap
against the drive gear.
5. Rotate the drive gear until the drive gear shaft retaining ring is
accessible and insert it into the groove in the gear case.
6. Install the drive housing onto the gear case See steps 26-31 in
“Drive Housing (pre-engaged) - Assembly and Installation” for
pre-engaged starters and steps 12-13 in “Drive Housing (inertia)
- Assembly and Installation”for inertia starters.
23. Remove the drive housing from the press.
24. Lubricate the drive housing O-Ring (78) with O-Ring lubricant
and install it onto the drive housing.
25. Insert the drive housing into the gear case in the same
orientation as previously noted. If orientation is lost, refer to
the model number and the appropriate orientation method
instruction page in this manual.
26. Secure the drive housing to the gear case using the drive housing
lock washers and cap screws. Tighten to 28-30 lb-ft [38-41 Nm] of
torque.
27. Using a 5/16” (8 mm) x 8”(203 mm) long hex inserted through
the threaded hole of the drive shaft, tighten the drive gear screw
to the drive gear (54) shaft. Tighten to 28-30 lb-ft [38-41 Nm] of
torque.
28. Slide the pinion return spring (81) over the helical splines of the
drive shaft and the pinion spring sleeve (82) over the pinion
return spring.
29. Coat the splines of the drive pinion (83) with Ingersoll Rand No.
130 grease and slide the pinion onto the drive shaft compressing
the pinion return spring.
30. Secure the drive pinion using the drive pinion washer (84) and
drive pinion screw (85). Tighten the drive pinion screw to 72-88
lb-ft (98-119 Nm) of torque for B and C ratio models and 115-135
lb-ft (156-183 Nm) of torque for D ratio models.
NOTICE
Right hand rotation starters have left hand threads. Left hand
rotation starters have right hand threads.

20 47113766_ed2
Retrot Installation
The following instructions outline the necessary steps required to
convert an ST900 or SS800 series starter to an ST1000M series starter.
ST900 Retrot
NOTICE
To convert an ST900 series starter to an ST1000M series starter,
the appropriate motor module must be purchased from an
authorized Ingersoll Rand distributor or Ingersoll Rand Engine
Starting Systems.
1. Make note of the orientation of the exhaust housing and motor
housing. If orientation is lost, refer to the model number and the
appropriate orientation method instruction page in this manual.
2. Consult the ST900 manual (accessible from www.
ingersollrandproducts.com) for instructions on removing the
motor housing assembly including the exhaust housing from the
intermediate gear case and remainder of the starter assembly.
3. Coat the rear gear case O-Ring (44) with O-Ring lubricant and
install the motor housing (1) assembly onto the intermediate
gear case (49) in the correct orientation.
4. Verify that the wave spring (7) is in the appropriate bore in the
exhaust housing. If needed, coat the wave spring lightly with
O-Ring lubricant to assist in securing the wave spring in place.
Install the exhaust housing (16) assembly into the motor housing
in the correct orientation.
5. Install the starter assembly cap screws (33) and lock washers (32)
and alternately tighten them to 49-61 lb-ft (66-83 Nm) of torque
in 20 lb-ft (27 Nm) increments.
6. Remove one of the magnetic plugs (4) and add 5.4 oz (160 mL) of
Dexron® II Automatic Transmission Fluid to the motor housing.
7. Coat the threads with SMB-441 and reinstall the magnetic plug.
Tighten to 5-10 lb-ft (7-14 Nm) of torque.
SS800 Retrot
NOTICE
To convert an SS800 series starter to an ST1000 series starter,
the appropriate motor module (see the“Parts List”section
in this manual), idler gear set assembly (ST1000- A108) and
intermediate gear case assembly (ST900-A37, ST900-A37C,
or ST900-A37D) must be purchased. For B ratio starters an
ST900-A37 intermediate gear case assembly is required. For C
ratio starters an ST900-A37C intermediate gear case assembly is
required. For D ratio starters an ST900-A37D intermediate gear
case assembly is required.
1. Make note of the orientation of the exhaust housing and motor
housing. If orientation is lost, refer to the model number and the
appropriate orientation method instruction page in this manual.
2. Consult the SS800 manual (accessible from www.
ingersollrandproducts.com) for instructions on separating the
motor housing from the gear case.
3. Pack the intermediate pinion (47) with 7.6-8.5 oz (225-250 mL)
Ingersoll Rand No. 130 grease.
4. Coat the rear gear case O-Ring (44) and front gear case O-Ring
(46) with O-Ring lubricant.
5. Place the intermediate gear case assembly with intermediate
pinion end rst into the gear case assembly in such a way that
the notch in the intermediate gear case faces the drive gear (54)
located in the gear case. See Dwg. 45548500 SH7.
Notch oriented such that
intermediate pinion and
drive gear may mesh fully.
(Dwg. 45548500 SH7)
NOTICE
Failure to align the intermediate gear case notch and drive gear
will result in damage to the starter and if attempted to put into
service will require disassembly and repair.
6. Install the idler gear set assembly by placing it over the rotor
pinion (30). Coat the threads of the three cap screws (40) with
243 Loctite® and secure the idler gear assembly to the motor
housing. Tighten the cap screws to 14 Nm (10 lb-ft) of torque.
7. Place the motor housing onto the intermediate gear case (49)
allowing the pinion to mesh with the idler gears (35).
8. Align the exhaust housing (16) assembly with the motor housing
in the desired orientation.
9. Install the starter assembly cap screws (33) and lock washers (32)
and tighten to 49-61 lb-ft (66-83 Nm) of torque in 20 lb-ft (27 Nm)
increments.
10. Remove one of the magnetic plugs (4) and add 5.4 oz (160 mL) of
Dexron® II Automatic Transmission Fluid to the motor housing.
11. Coat the threads with SMB-441 and reinstall the magnetic plug.
Tighten to 7-14 Nm (5-10 lbft) of torque.