Ingersoll-Rand ST400 Series Setup guide

P7061
03539319
Edition 3
January 2010
Save These Instructions
Turbine Powered Starters
Model ST400
Installation and Maintenance
Information

2 03539319_ed3
Product Description
These compressed air powered Turbine Engine Starters are intended to be incorporated into a system, the primary purpose of which is to
initiate operation of reciprocating internal combustion engines.
WARNING
General Product Safety Information
Read and understand this manual before operating this product.
It is your responsibility to make this safety information available to others that will operate this starter.
Failure to observe the following warnings could result in injury.
WARNING
Product Safety Information - When Placing the Starter in Service
Always install, operate, inspect and maintain this product in accordance with all applicable standards and regulations (local, state,
country, federal, etc.).
Operate ST400 Starters on compressed air only. They are not designed or sealed for operation on compressed gas.
Be sure all air supply, lines & ttings are of the proper size and tightly secured.
Ensure an accessible emergency shut-o valve has been installed in the air supply line, and make others aware of its location.
Always use clean dry air at pressures not to exceed the maximum inlet pressure rating stamped on the product nameplate. Higher
pressure may result in hazardous situations including excessive speed, rupture or incorrect output torque.
Always turn o the air supply and disconnect the air supply hose before installing, removing or adjusting any accessory on this
starter, or before performing any maintenance on this starter.
Operate this starter only when properly installed on the engine.
Do not use damaged, frayed or deteriorated air hoses and ttings.
Use only proper cleaning solvents to clean parts. Use only cleaning solvents which meet current safety and health standards. Use
cleaning solvents in a well ventilated area.
Do not remove any labels. Replace any damaged label.
Starter is not insulated from electric shock.
Starters weigh in excess of 25 pounds (11.3 kgm). Use caution when handling.
WARNING
Product Safety Information - When Using the Starter
Always wear eye protection when operating or performing maintenance on this starter.
Always wear hearing protection when operating this starter.
Use accessories recommended by Ingersoll Rand.
Particles in the air system may pass through the starter during operation. Avoid the path of the exhaust ow during starter
operation.
Safety Symbol Identication
Wear Respiratory
Protection
Wear Eye
Protection
Wear Hearing
Protection
Read Manuals Before
Operating Product
(Dwg. MHP2598)
Parts and Maintenance
CAUTION
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 in 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 starter has expired, it is recommended that the starter be disassembled, degreased and parts be separated by
material so that they can be recycled.
Manuals can be downloaded from www.ingersollrandproducts.com
Refer all communications to the nearest Ingersoll Rand Oce or Distributor.
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03539319_ed3 3
How to Order a Starter
ST400 IC 03 R 31-030
ST400 - 44% ARC
(MAX. 150 PSI)
ST455 - 55% ARC
(MAX. 120 PSI)
ST499 - 99% ARC
(MAX. 90 PSI)
I - 1” NPT INLET
NO LETTER - SAE
SPLIT FLANGE INLET
C - GEAR RATIO
00 - CRADLE MOUNT
01 - SAE 1 FLANGE
03 - SAE 3 FLANGE
R - RIGHT HAND
L - LEFT HAND
31- PINION CODE
ORIENTATION
When ordering a Starter, refer to table below for correct pinion data.
TEETH BLANK D.P. MOD. P.A. ROTATION PINION
10 10 8/10 20 DEG RIGHT ST400-13-15
12 12 8/10 20 DEG RIGHT ST400-13-29
12 12 6/8 20 DEG RIGHT ST400-13-31
12 12 6/8 20 DEG LEFT ST400-13-32
9 9 3 15 DEG RIGHT ST400-13-77
11 11 3 15 DEG RIGHT ST400-13-85
11 12 8/10 20 DEG RIGHT SS350R-13-21
13 14 3.5 15 DEG RIGHT SS350R-13-895
24 12/14 12 DEG LEFT SS175L-13-1448
10 11 I0/12 20 DEG RIGHT 04335055
9 10 15 DEG RIGHT 04595799
17 18 3.5 15 DEG RIGHT 04334371
11 3.5 20 DEG RIGHT 04333969
13 13 3.5 15 DEG RIGHT 04332292
14 16 3.5 15 DEG RIGHT 04595807
14 3.5 14.5 DEG LEFT 04334363
12 4 14.5 DEG LEFT 04331724
14 15 3.5 20 DEG LEFT 04334389
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

4 03539319_ed3
Orientation of the Air Starter
We recommend that starters be ordered to proper orientation for
your specic mounting or installation requirements. However, if the
starter must be reoriented for installation, proceed as follows
Loosen six ange screws.
Turn Flange to desired orientation. Note the orientaion marks on
the exterior ofthe Housing. Each mark measures 30° of arc. There
is a “0”mark which alligns with the starter inlet.
Tighten the six ange screws to 3-4 ft. lbs. (4-6 Nm) torque.
To purchase pre-oriented starter:
It is necessary to provide the orientation code which is the angle
of the Mounting Flange relative to the starter inlet port (“0”mark
on the Housing). Therefore, the orientation code will be an angular
measurement. To obtain the orientation code, proceed as follows:
1.
2.
3.
Orient the starter so that the inlet port is pointed straight up. The
“0” mark on the Housing near the Mounting Flange should be
visible and pointed straight up.
With the starter at this setting, position yourself so that the Drive
Pinion (2) is facing you.
Rotate the Mounting Flange clockwise until the desired
orientation is reached.
You will derive the orientation code from a clockwise
measurement of the angle from the“0” mark (inlet port) to the
reference hole of the Mounting Flange. The Housing has indicator
marks every 30° . Example: ST400C03R31-060.
1.
2.
3.
4.
0
180
SAE 03 Flange
SAE 01 Flange
210
90
60
30
240
120
Left Hand
Rotation
150
270
300
330
Ref. Hole
of Mounting Flange
Ref. Hole
of Mounting Flange
Right Hand
Rotation
(Dwg. TPD1670-1)
How to Order System Components
ST400-C339 Electronic Valve ST400-A339M Manual Valve


45° Split Flange /37° Flare
ST400-23
90° Split Flange /37° Flare
ST400-162


Split Flange /37° Flare
ST400-25





03539319_ed3 5
Flange Kit ST400-K17
Kit Includes :
Flange, O-ring, Bolts (4), Washer (4)
90 ° Tank Flange ST400-161
Reducer Bushing ST400-81
ST400-16 Flange Assembly (2)
(REF) Torque
Bolts 28-34 Ft. lbs
1” NPT Thread
Ø .406
4 Holes
4 Holes (Threaded)
Swivel Flange
2.31
1.03
2.062 2.75
2.38
2.38
1 1/4-11 1/2 NPT
1-11 1/2 NPT
1.47
10
Push Button Control Valve
Part Description
Part Number
Chrome Plate
SMB-618
SMB-G618
12
Pressure Gauges 150 psi
Part Description
Part Number
150BMP-1064 1/8 NPT DASH MNT.
1/4 NPT TEE` MNT.
150BMP-1064L
13
7/16-20
SAE 37 º FLARE
Connector
1/8-27
NPT
Part Description
Part Number
ST400-52 Male Connector
11 Solenoid Actuated Control Vlave
Pioneer
P/N 15300002
Part DescriptionVoltage
Part Number
Pioneer Connector P/N 15300002
Loose Wires
Loose Wires
150BMP-1051B 12V DC
12V DC
150BMP-A1051C
24V DC
150BMP-2451B
Flange
Part Description
Part Number
ST400-16 Flange Kit
.52
.94
.62
ø .41
2.06 2.75
(Dwg.TPD1660-1)
(Dwg.TPD1662)
(Dwg.TPD1664-1)

6 03539319_ed3
Placing System in Service
NOTICE
When connecting the starter to an air receiver tank that is already in service, bleed o the air pressure in the tank prior to installation.
Valve
Mount the ST400-A339 or ST400-B339 Electronic Valve or ST400-A339M Manual Valve to the air receiver as shown in the installation
diagrams.
Air ow arrow must point toward the starter.Using the supplied ange tting, tighten the four ange bolts to 28-35 ft-lbs (38-47 Nm) torque.
For electrical installations, install the ST400-A618 Electrical Switch on the dash panel. See Dwg. TPB973 for making wire connections. For air
installations, install the SMB-618 Starter Control Valve on the dash panel. Connect the air lines as shown in Dwg. TPB976.
Mounting the Starter
To determine the exact length of #16 hose required, run a piece of hose or some other exible tubing of the same diameter from the valve
on the air receiver to the starter mounting location on the engine. After determining the hose length required, attach O-ring sealed ange
ttings as required.
Attach the hose to the outlet side of the valve with the ST400-16 4 bolt split-ange provided. Tighten bolts to 28-35 ft-lbs (38-47 Nm) torque.
At this point, determine if it is convenient to attach the hose to the starter before actually mounting it on the engine.
If possible, liberally grease the teeth of the ring gear with a good, sticky gear grease or motorcycle chain lubricant. This will help to promote
the life of the starter pinion and engine ring gear.
Mount the starter in position and bolt it to the engine.
System Actuation
Pressurize the complete starting system and using a soapy solution, check the following locations in the live air line for leaks:
Valve/tank connection
Fill-line to check valve on ST400 valve
Air supply line to 2-way check valve
1.
2.
3.
1.
2.
3.
4.
5.
•
•
•
ST400 Installation Diagram - Stationary Industrial
�Inlet Flange Kit
ST400-K17
�Relay Valve 1”
SRV100 Or ST400-A339M
High Pressure
Supply
ST900-267-16
Strainer
1” Hose
# 4 Hose 1/4”
# 4 Hose 1/4”
Air Pressure Gauge
�150BMP-1064L (Air Only)
NOTE :
Use sealant on All pipe Connections.
� SMB-441
� Ingersoll Rand Part Numbers
(Dwg.TPA1592)

03539319_ed3 7
ST400 Installation Diagram - Electro - Mechanical
+12 Volt Power Supply Gladhand
Connector
Push Button
Start Switch Should be
Sealed.
(P/N HSPPS-3) Refer Air from
Dry Tank
(Air Supply)
#8 Hose (1/2”)
PIN A
PIN B
4
4
4
2
3
3
9
7
3
3
1
1
2
3
4
5
7
9
5
Starter
Description
Tank
Fitting
Flange
Hose
Switch
Diaphragm Valve
#
(Dwg. TPB973-1)
ST400 Installation Diagram - Manual
Gladhand
Connector
Should be
Sealed.
(P/N HSPPS-3) Refer Air from
Dry Tank
(Air Supply)
#8 Hose (1/2”)
#4 Hose (1/4”)
3
3
2
1
11
12
13
13
10
5
3
3
4
44
8
Description
1
2
3
4
5
8
10
11
12
13
Starter
Tank
Fitting
Flange
Hose
Diaphragm Valve
Push Button Valve
Solenoid (Optional)
Gauge
Connector
(Dwg. TPB976)

8 03539319_ed3
ST400 Starter Dimensions
1.138
28.9
R 250 6.4 TYP.
R 0.256 6.5 TYP. 45 °
TYP.
R 500 12.7 TYP.
2.857 72.8
5.682 144.3
5.030 127.8
3.125
79.4 3.693
93.8
5.030
128
3.750
95.2
2.950
74.9
1.740
44.2
1.250
31.8
Pinion
Travel
Ring Gear Face
2.000
50.8
.250
6.4
.260
6.6
12.178
309.3
.500 12.7
2.173
55.2
1.490
37.8
13.918
353.5
2.500
63.5
3.499 3.495
.425 10.8
88.9 88.8
2.060
52.3
2.220
58.4 1.000
25.4
3/8-16 UNC
.520 13.2 1.030
28.2
1.039
26.4
R
2.875
73.0
R
SAE 1 Flange
SAE 3 Flange
Pilot
Dia.
3.624 3.620
92.0 91.9
Pilot
Dia.
3 Places
.659 16.7
.406 10.3
2.062
52.4
2.293
58.2
1.031
26.2
1.031
26.2
.516 13.1
1-11 1/2 NPTF
3 Places
90 °
120 °
Dual Inch Dimensions mm
Notes : 1. Weight 24lbs (11.0 Kg) 2. Flange Rotation Ininite Refer marks Every 30 °
2.062
52.4
1.031
26.2
4 Holes
3/8-16 UNC
2.289
58.1
.516 13.1
2.820
71.6
(Dwg.TPA1400-1)

03539319_ed3 9
ST400-C339 Electonic Valve
ST400-16 Flange Assembly (2) Ref. Torque Bolts
28-34 Ft. lbs.
ST400-950P Pressure Coil
Push Type
Manual Override
Hidden by 1/8 NPT Plug
292.1 266.7
11.500 10.500 26.127
25.873
1.029 1.019
13.127 12.873
0.517 0.507
26.127 25.873
1.029 1.019 52.127
51.873
2.052 2.042
149.05 142.95
5.868 5.628
118.05 111.95
4.648 4.408
1.0” Flange Style
Two 1/4-18 NPT Test Points
Torque 15±3 lb. Ft Self Locking Nut
3/8-16 UNC-3B Locking Helicoil X1.5 Ø Helicoil # 3585-6CN-0562 4 Places
Inlet Check Valve 1/2”-14 NPTF

10 03539319_ed3
ST400-A339M Manual Valve
1/2-14 NPT
1/8-27 NPT
1.38 34.93
�
(REF) Torque Bolts 28-34 Ft. lbs (38-46 N-m)
5.03
127.76
3.07
78.04 1.96
49.72
1/4-18 NPT
Tank Pressure
1/4-18 NPT
Tank Pressure
1.0 “ Flange
Style
1.66
42.14
1.69
42.90
5.78
146.70
3.56
90.55
3.35
85.05
1.0 “ Flange
Style

03539319_ed3 11
ST400 Turbine Powered Starter- Exploded View
12
11
10
9
8
6
7
17
17
5
5
15
15
16
16
4
4
3
3
2
1
13
14
9
(Dwg.TPA1374-1)

12 03539319_ed3
ST400 Turbine Powered Starter- Parts List
Item Part Description Part Number Item Part Description Part Number
1 Drive Pinion Screw SS350-394 5 Flange
2 Drive Pinion SAE 1 Flange ST4W300-01
for ST400CO1R15 ST400-13-15 SAE 3 Flange ST400-300-03
for ST400C03R21 ST400-13-21 6 Nameplate ST400-301
for ST400C03R29 ST400-13-29 7 Nameplate Tack ST400-100
for ST40OC03R31 ST40013-31 8 Return Spring ST400-700
for ST400C03R071 04335055 9 Liner Assembly
for ST400C03R77 ST400-13-77 Standard Arc Right Hand ST400-A41R
for ST400C03R79 04595799 Standard Arc Left Hand ST400-A41L
for ST400C03R85 ST400-13-85 55 % Arc Right Hand ST455-A41R
for ST400C03R91 04595807 55 % Arc Left Hand ST455-A41L
for ST400C03R95 04334371 Full Arc Right Hand ST499-A41R
for ST40OC03R832 04333969 Full Arc Left Hand ST499-A41L
for ST40OC03R893 4332292 10 Housing Cover Gasket ST400-283
for ST40OC03R895 SS350-13-895 11 Housing Cover ST400-562
for ST40OC03L30 ST400-13-32 12 Housing Cover Bolts (4) ST400-563
for ST400C03L32 ST400-13-32 13 Housing 04615092
for ST400C03L92 04334363 14 Vent Plug ST400-546
for ST400C03L101 04331724 15 Front Drive Shaft Bearing ST400-363
for ST400C03L895 ST400-13-32 16 Drive Housing Seal ST400-271
for ST40OC03L942 04334389 17 Inlet Flange Assembly 04564522
Or
ST400-16
for ST400C03L1448 SS175L-13-1448 (includes Flange (2), Flange Mounting
3 Flange Cap Screws (6) 04564522 Bolts (4), Lock Washers (4) and O-ring)
4 Flange Cover Starters with “I”in model number ST400-K17
for SAE 1 Flange ST400-480-01
Or 04615118
for SAE 3 Flange ST400-480-03
Or 04615100
for Cradle Mounting 04332334

03539319_ed3 13
Maintenance, Disassembly / Assembly Instructions for Starter
WARNING
Always wear eye protection when operating or performing any maintenance on this starter. Always turn o the air supply and
disconnect the air supply hose before installing, removing or adjusting any accessory on this starter or before performing any
maintenance on this starter.
Disassembly
General Information
Do not disassemble the Starter any further than necessary to
replace worn parts.
When grasping a part in a vise, always use leather-covered or
copper-covered vise jaws to protect the surface of the part and
help prevent distortion. This is particularly true of threaded
members.
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 Model ST400 Starter. Never reuse old
seals or gaskets.
When disassembling, always mark adjacent parts so the members
can be located in the same relative position when the starter is
reassembled.
Never wash the Liner Assembly (9) in a solvent.
Disassembly of the Starter
Remove the Drive Pinion Screw (1) from the drive shaft and
remove the Drive Pinion (2).
1.
2.
3.
4.
5.
6.
1.
Remove the six Flange Cap Screws (3) from the Housing (13).
Remove the Flange Cover (4) and Flange (5) simultaneously by
pulling up on the Flange.
Remove the Front Drive Shaft Bearing ( 15) from the Flange Cover.
Remove the Drive Housing Seal (16) from the Flange Cover.
Turn the starter over and secure it vertically in a xture.
NOTICE
Use care when removing the Housing Cover Bolts (12) holding
the Housing Cover (11) to the starter. The Liner (9) is spring
loaded and will protrude approximately one inch beyond the
Housing when released.
To remove the Housing Cover (1l), slowly loosen the four Housing
Cover Bolts (12) while holding the Housing Cover (11) in place.
Slide the Liner Assembly (9) out of the Housing.
Remove the Return Spring (8).
2.
3.
4.
5.
6.
7.
8.
9.
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 or housings.
Assembly of the Starter
Place the Housing (13), front end down so that the Return Spring
(8) can be placed into the Housing.
Slide the Liner Assembly (9) into the Housing. Orient the Liner so
that the notch aligns correctly with the Housing inlet port and
Liner air inlet port aligns with the Housing air inlet port. Attach
Housing Cover Gasket (10) to Housing Cover.
Attach the Housing Cover (11) to the Housing with just one
Housing Cover Bolt (12). Engage only a few threads so that the
Housing Cover can be easily rotated.
1.
2.
3.
1.
2.
3.
While pushing the Liner Assembly down against the Return
Spring, rotate the Housing Cover over the Liner to hold it down.
Tighten the Housing Cover Cap Screws to 5-6 ft-lb (6.7-8 Nm)
torque.
Press the Drive Housing Seal (16) into the Flange Cover (4) with
the sealing lip pointed down.
Press the Front Drive Shaft Bearing (15) into the Flange Cover.
Fit the Flange (5) onto the Flange Cover so that the counterbore of
the Flange slides over the shoulder of the Flange Cover correctly.
Carefully slide this assembly over the drive shaft. Be careful not to
tear the Seal lip. Orient the Flange correctly.
Apply Loctite to the six Flange Cap Screws (3). Torque to 3-4 ft-lb
(4-5.4 Nm) .
Attach the Drive Pinion (2) to the drive shaft using the Drive
Pinion Cap Screw (1) and tighten to 53-58 ft-lb (72-79 Nm) torque
with loctite.
4.
5.
6.
7.
8.
9.
10.
11.
Test and Inspection Procedure
WARNING
When 90 psig air pressure is applied to the starter, the Drive Pinion will be rotating at 2,800 rpm and Drive Shaft and Drive Pinion will
move forward 1.25”. Keep face and hands away from rotating Drive Pinion.
CAUTION
Do not run the starter at free speed.
Orientation:
Mounting Flange must be oriented per the customer’s order or engineering drawing. If orientation is not specied by customer, standard
orientation will be supplied. Check orientation print on page 5.
Conrm Overrunning of Clutch:
Turn the Drive Pinion by hand in the direction of rotation. The clutch should ratchet smoothly.
Conrm Drive Rotation:
Turn the Drive Pinion by hand in the direction opposite of rotation. The clutch should not ratchet.

14 03539319_ed3
Manual Valve Assembly ST400-A339M - Exploded View
16
9
3
4
2
7
1
15
4
8
8
4
6
4
5
(Dwg. TPA1402-1)
Manual Valve Assembly ST400-A339M - Part List
Item Part Description Part Number Item Part Description Part Number
1 Valve Housing ST400-339 7 Check Valve ST400-1056
2 O-ring Y325-010 8 Plug (2) HSPPS-2
3 Housing Cover ST400-338M 9 Cover Screws (6) Y222-156-C
4 Valve Kit
ST400-K619
15 Flange Assembly
ST400-16
(includes O-ring, Plunger and Pin (includes Inlet Flange (2 halves),
Assembly, Grommet Seal and Flange Mounting Bolts (4), Lock Washers (4)
Diaphragm Assembly) and O-ring)
5 Cap ST400-616A 16 Male Connector ST400-52
6 Spring ST400-615A

03539319_ed3 15
Maintenance, Disassembly / Assembly Instructions for Manual Valve
WARNING
Always wear eye protection when operating or performing any maintenance on this starter. Always turn o the air and electrical
supply and disconnect the air and electrical supply before installing or removing any component on this valve, before making any
adjustments on this valve or before performing any maintenance on this valve.
Disassembly
General Information
Do not disassemble the valve any further than necessary to
replace worn parts.
When grasping a part in a vise, always use leather-covered or
copper-covered vise jaws to protect the surface of the part and
help prevent distortion. This is particularly true of threaded
members.
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 the valve. Never reuse old seals or
gaskets.
1.
2.
3.
4.
Disassembly of the Valve
Unscrew the Check Valve (7) from the Valve Housing (1). Remove
Plugs (8) from the Valve Assembly.
Remove the six Cover Screws (9) from the Cover and Valve
Housing.
Remove the Diaphragm (4) from the Valve Housing and the O-ring
(2) from the pocket in the Valve Housing.
Unscrew the Cap (5) from the Valve Housing. Remove the O-ring
(4) from the Cap. The Spring (6) and Plunger should come out
with the Cap. If not, remove them from the Valve Housing.
Remove the Grommet (4) from the Valve Housing.
1.
2.
3.
4.
5.
Assembly
General Information
Whenever grasping a valve or part in a vise, always use leather-
covered or copper-covered vise jaws. Take extra care with
threaded parts or housings.
Apply a lm of o-ring lubricant to all O-rings before nal assembly.
Assembly of the Valve
Insert the rounded end of the Grommet (4) in the top of the
Valve Housing (1) through the valve body hole. The top can be
identied by the concentric raised rings.
Lubricate the O-rings on the Valve Stem (4) and Plunger (4) with
O-ring Lubricant. Push this assembly through the Grommet from
the bottom of the Valve so that the Plunger seals on the valve
seat.
Turn the Valve Housing over and place the Spring (6) on the
Plunger with the smaller diameter of the Spring leading.
1.
2.
1.
2.
3.
Place the large O-ring (4) on the Cap (5). Guide the Spring and
Plunger into the Cap while screwing the Cap into the Valve
Housing. Tighten the Cap until it seats snugly against the Valve
Housing.
Place the O-ring (2) into the pocket of the Valve Housing.
Place the Diaphragm (4) on the Valve Housing, making sure that
the punched hole of the Diaphragm is aligned over the O-ring
and that the plastic disk of the Diaphragm is up.
Set the Housing Cover on the Valve Body so that the O-ring
shoulder ts into the diaphragm hole.
Attach the six Cover Screws (9) through the Cover and Diaphragm
and into the Housing. Alternately tighten the Screws to
45-55 in - lb (5.1 - 6.2 Nm) torque. Screw the Check Valve (7) into
the Valve Body to 40-50 ft/lbs (54-67Nm).
4.
5.
6.
7.
8.
Test and Inspection Procedure
Solenoids: Using a solenoid tester, apply 9 VDC minimum to 24 VDC maximum to Solenoid. The Solenoid should activate the Armature with a
minimum 9 volt charge and a“clicking” sound indicates that the Solenoid is functioning properly. Follow this procedure for both the Exhaust
Solenoid and the Pressure Solenoid.

16 03539319_ed3
Troubleshooting
Air Starter System Diagnosis ST400 Starter
Valve opens - Starter blow-by
Starter does not Engage
Check drive pinion for damage. Make sure that the correct drive pinion is
on the starter. Replace drive pinion if necessary. Check for damaged ywheel.
Check for blockage in internal housing port of starter. Remove blockage. Check
main supply hose for blockage or hose apper. Remove blockage or replace hose.
Check system air pressure. Use truck tire gauge on
Schrader valve located on starter control valve.
Should be 120 psi.
Cranks
Ok
Cranks
Ok
Cranks
Ok
Cranks
Ok
No, presssure is not 120 psi Yes, presssure is 120 psi
Fill to 120 psi
Still Blow-by
Starter blow-by
A B
Still Blow-by
Malfunctioning Valve - Drain air from reservoir rst by removing 1/4” plug on starter
valve opposite tank ll. Loosen cap on Bottom of valve. Inspect plunger for damage
and/or proper lubrication. Lubricate or replace the plunger if necessary. Measure
resistance of solenoid coils. Resistance should be approximately 30 ohms. Replace
solenoid coils if necessary.
* Refer to Page 14-15 for valve maintenance.
Valve checked
Valve operates properlyRemove starter - inspect ring gear for damage.
Roll engine to inspect ring gear teeth. Check
starter pinion for damage.

03539319_ed3 17
Replace Damaged Gear
Cranks
Ok
Re-install Starter
Cranks
Ok
Cranks
Ok
Still Cranks slow
If extreme cold, check cold
starting aids for proper operation.
(i.e Ether System works, Block Heater
works)
Cranks
Ok
No Damage of Ring Gear or
Pinion
Replace with New Starter
A B
Low Power - Cranks engine slow
Follow instructions on Page 16

18 03539319_ed3
Cranks
Ok
Cranks
Ok
Cranks
Ok
Valve operates properly
Starter will not stop operating or
Starter cuts out too soon
Check system wiring
Refer to Pg. 7 Dwg. TPB973-1
Malfunctioning Valve - Drain air from reservoir rst by removing 1/4” plug on starter
valve opposite tank ll. Loosen cap on Bottom of valve. Inspect plunger for damage
and/or proper lubrication. Lubricate or replace the plunger if necessary. Measure
resistance of solenoid coils. Resistance should be approximately 30 ohms. Replace
solenoid coils if necessary.
* Refer to Page 14-15 for valve maintenance.
Check system oil pressure
lockout switch (Terminal 150).
If malfunctioning: replace