Form P7648
Edition 1
August 2004
CCN 04579728
Operation and Maintenance Manual
for
Series SRV125F
Starter Relay Valve
NOTICE
Series SRV125F Starter Relay valves are designed for controlling fluid flow in conjunction with Air Starting
Systems.
WARNING
• IMPORTANT SAFETY INFORMATION ENCLOSED - SAVE THESE INSTRUCTIONS.
• Read and understand this manual before operating Valve.
• Failure to observe the following warnings could result in injury.
PLACING THE VALVE IN SERVICE
•
Always install, operate, inspect and maintain this prod-
uct in accordance with all applicable standards and reg-
ulations (local, state, country, federal, etc.).
Always use clean, dry air at a pressure which does not
exceed the pressure rating listed on the valve.
Do not use damaged, frayed or deteriorated air hoses &
fittings.
Always turn off the air and disconnect the air hose
before installing, removing or adjusting any accessory
on this valve, or before performing any maintenance on
this valve or accessory.
Do not lubricate the valve with flammable or volatile
liquids such as kerosene, diesel or jet fuel, use only
recommended lubricants.
Series SRV125F Valves are not designed for working
in explosive atmospheres.
•
•
Do not remove any labels, replace any damaged labels.
Operate this valve only when properly installed in the
Air Starting System.
Always bleed off the air pressure before attempting to
remove the Starter Relay Valve from the Receiver or
before attempting to perform any maintenance on the
Starter Relay Valve.
Never attempt to remove the Retaining Ring (12) from
the bottom side of the Starter Relay Valve until the air
pressure has bled off. If the Retaining Ring is removed
while there is pressure in the Receiver, internal parts of
the Starter Relay Valve will be blown out with consid-
erable force.
•
•
•
•
•
•
•
•
Use only recommended Ingersoll-Rand accessories.
Refer All Communications to the Nearest
Ingersoll-Rand Office or Distributor.
© Ingersoll-Rand Company 2004
Printed in U.S.A
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EXPLODED VIEW AND PARTS LIST
SERIES SRV125F STARTER RELAY VALVE
(Dwg. TP2184)
When ordering, use applicable part number
Item
Part Description
Part Number Item
Part Description
Part Number
SRV150-338
Y327-143 *
1
2
3
4
5
6
7
8
9
*
+
Valve Housing . . . . . . . . . . . . . . . . . . . .
Pipe Plug (2 required) . . . . . . . . . . . . . .
Upper Piston O-Ring . . . . . . . . . . . . . . .
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bumper. . . . . . . . . . . . . . . . . . . . . . . . . .
Piston O-ring . . . . . . . . . . . . . . . . . . . . .
O-ring Retainer. . . . . . . . . . . . . . . . . . . .
Spring . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Plug O-ring . . . . . . . . . . . . . . . . . . .
SRV125F-40
HSPPS-2
10
11
12
13
End Plug . . . . . . . . . . . . . . . . . . . . . . . . .
End Plug Seal O-ring . . . . . . . . . . . . . . .
Retaining Ring . . . . . . . . . . . . . . . . . . . .
Warning Label. . . . . . . . . . . . . . . . . . . . .
SRV150-210 *
SRV150-246
SRV150-339 *
SRV150-211 *
SRV150-33 *
SRV150-250
SRV150-67 *
SRV150-340 *
04333274
+
+
+
Tune Up Kit. . . . . . . . . . . . . . . . . . . . . . .
Pipe Sealant. . . . . . . . . . . . . . . . . . . . . . .
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRV150-TK3
SMB-441
SRV-GR55 *
Indicates parts available in Tune Up Kit
Items Not Shown
3
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OPTIONAL EQUIPMENT
(Dwg. TP2212)
When ordering, use applicable part number
Item
Part Description
Part Number
Item
Part Description
Part Number
Solenoid and Mounting Hardware - Position 1
Pilot Port Hardware - Position 2
A
Solenoid
12 Volt, Pioneer Connections . . . . . . . .
L
90° Elbow with Push to Lock . . . . . . . . .
90° Elbow with JIC 37° . . . . . . . . . . . . .
EL90-4M4DOT
EL90-4M437M
150BMP-A1051C
150BMP-1051B
150BMP-2451B
EL90-4M4DOT
150TMP-2451
Y133-105C
M
12 Volt, Wire Leads . . . . . . . . . . . . . . .
12 Volt, Wire Leads . . . . . . . . . . . . . . .
90° Elbow with Push to Lock . . . . . . . . . . .
Solenoid Mounting Bracket. . . . . . . . . . . . .
Solenoid Mounting Screw (2) . . . . . . . . . . .
Solenoid Mounting Screw Washer (2). . . . .
Solenoid Mounting Bracket Screw (2) . . . .
Solenoid Mounting Bracket Washer (2) . . .
90° Elbow with Push to Lock . . . . . . . . . . .
Connection Hose . . . . . . . . . . . . . . . . . . . . .
90° Elbow with Push to Lock . . . . . . . . . . .
Connection Hose . . . . . . . . . . . . . . . . . . . . .
Items Not Shown
Left and Right Live Air Port hardware - Position 3 and 4
N
O
P
90° Elbow with Push to Lock . . . . . . . . .
T Connection with Push to Lock . . . . . .
Schrader Valve . . . . . . . . . . . . . . . . . . . .
1/4” Pipe Plug. . . . . . . . . . . . . . . . . . . . .
T Fitting with 1/4” NPT . . . . . . . . . . . . .
Pressure Gauge . . . . . . . . . . . . . . . . . . . .
EL90-4M4DOT
150TMP-MRT4M4
04333654
B
C
D
E
Q
R
+
HSPPS-2
Y117-110
SRV125F-188
SRV125F-1064
F
150TMP-128
Y14-516C
G
H
I
Secondary Inlet Port Hardware - Position 5
EL90-4M4DOT
150TMP-125
EL90-4M4DOT
150TMP-125
S
T
U
Check Valve . . . . . . . . . . . . . . . . . . . . . .
Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1/4” Flange Kit . . . . . . . . . . . . . . . . . .
ST400-1056
SRV125F-34
ST500-K166
J
K
(+)
For Position Coding information refer to Drawing 10554749
4
P7648 Edition 1
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PLACING THE STARTER RELAY VALVE IN SERVICE
Installation
WARNING
Always wear eye protection when performing any mainte-
nance on this valve.
1. Place the O-Ring supplied with the flange fitting into the
groove on the Starter Relay Valve.
2. Mount the Starter Relay Valve to the tank using ST500-K166
Flange Assembly. The air flow arrow must point toward the
starter.
Pre-Installation
3. Check the O-Ring to see that it properly seated in the groove
to prevent cutting.
4. Push the two clamp halves inward as far as they will go.
5. Tighten the four flange bolts in an alternating pattern to
35-45 ft-lbs (47-61Nm) torque.
6. Attach the air hose from the outlet side of a 3-way normally
vented Control Valve to the small tapped hole in the top of
the Starter Relay Valve. Use SMB-441 Ingersoll-Rand Seal-
ant on the male thread.
1. Clean the air line, o-ring groove and sealing surfaces to be
sure they are free of foreign material.
2. Ensure that enough space is left for removal and service of
this valve.
3. Ensure that the air line is suitably aligned and supported to
avoid strained joints.
4. Do not over tighten the air line connections.
5. All Starter Relay Valves are to be installed with the Valve in
the vertical position.
NOTICE
This Starter Relay Valve is specially designed and
manufactured by Ingersoll-Rand for use on Starter
Installations. Install it in accordance with the following
instructions.
5
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MAINTENANCE
Installation of the Tune Up Kit
Disassembly of the Starter Relay Valve
WARNING
1. Bleed off the air pressure.
Always wear eye protection when lubricating or performing
maintenance on the Starter Relay Valve. Always bleed off the
air pressure before lubricating or performing any mainte-
nance on the Starter Relay Valve.
2. Clamp the Starter Relay Valve in a vise with the Retaining
Ring (12) facing up.
3. Carefully remove the Retaining Ring. The End Plug (10)
should spring out. If it does not, tap the Valve Housing (1)
lightly with a soft hammer until the End Plug springs out.
4. Remove the End Plug, Spring (8), and Piston Assembly (4).
5. Remove and discard all of the used O-Rings and the Bumper
(5).
Lubrication
Periodically lubricate the Starter Relay Valve as follows:
1. Bleed off the air pressure.
2. Disconnect the No. 4 Hose from the tank at the control air
supply port near the bottom of the Starter Relay Valve oppo-
site the air inlet. In some installations, this ¼" N.P.T. will be
plugged.
3. Remove the plug. Squirt approximately 1 ounce (30 cc) of
10W oil into the Starter Relay Valve through the hose plug
opening.
6. Clean all other parts in a clean, suitable cleaning solution in a
well ventilated area.
Assembly of the Starter Relay Valve
1. Using O-Ring lubricant, lubricate and install the new Piston
O-Ring (6) and the new Upper Piston O-Ring (3) on the Pis-
ton (4).
4. Reconnect the hose or reinstall the plug.
NOTICE
The Upper Piston O-Ring (3) is slightly larger in diameter
than the End Plug O-Ring (9).
2. Turn the Piston over and install the new Bumper (5).
3. Using O-Ring lubricant, lubricate and install the new End
Plug Seal O-Ring (11) and the new End Plug O-Ring (9) on
the End Plug (10).
NOTICE
No. SRV150-TK3 Tune Up Kit is available for maintaining the
Starter Relay Valve. This Tune Up Kit includes all O-Rings
(3,6,9,11), Bumper (5), O-Ring Retainer (7), End Plug
Retaining Ring (12) and Grease.
4. Lubricate the lower small bore of the Valve Housing (1) with
O-ring lubricant.
5. Insert the Piston Assembly into the Valve Housing until the
Piston O-Ring (6) seats against the beveled face.
6. Install the O-Ring Retainer (7) with the large opening over
the Piston O-Ring.
7. Place the Piston Spring (8) on the Piston.
8. Place the End Plug Assembly on the Piston Spring.
9. Using a press to hold down the End Plug Assembly, install
the End Plug Retaining Ring (12).
6
P7648 Edition 1
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NOTES
P7648 Edition 1
7
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SERVICE CENTERS
United States
Latin America
Asia/Pacific
Ingersoll-Rand – Latin America
IR ESS Customer Service /Distribution Division
Australia
Center
P.O. Box 618
730 Northwest 107 Avenue
Street 300
Ingersoll-Rand Australia. Ltd
1 Hartnett Drive
510 Hester Drive
White House, TN 37188
United States
Phone: (888) START-AIR
Fax: (615) 672-0801
Miami, FL 33172
Phone: (305) 559-0500
Fax: (305) 222-0864
PMB 2, Carrum Downs BC, Vic.,
3201
Seaford, Victoria 3198
Australia
Phone: (61) 3 9554 1600
Fax: (61) 3 9554 1611
Brasil
Ingersoll-Rand do Brasil Ltda.
Tool & Hoist Division
Canada
Marketing/Sales/Service Headquarters Av. Dr. Cardoso de Meio 1855
India
Ingersoll-Rand Canada Inc.
51 Worcestor Road
cj. 152-04548-005 Sao Paulo,. SP
Brasil
Ingersoll Rand Wadco Tools Ltd.
37-A, Site 4
Toronto, Ontario M9W 4K2
Phone: (416) 213-4500
Fax: (416) 213-4510
Phone: (55) 11 3049-8900
Fax: (55) 113846-4985
Sahibabad Industrial Area
Ghaziabad 201 010 (U.P.)
India
Chile
Phone: (0120) 477-1001/2/3/4
Fax: (0120) 477-1005
Europe/ Middle East/ Africa
Ingersoll-Rand Tool & Hoist Division
Zone du Chene Sorcier
BP 62
78346 Les Clayes sous Bois Cedex
France
Ingersoll-Rand Chile
Nueva Tajamar 555, 15th fl.
Las Condes, Santiago
Chile
Phone: (56) 2 339-7939
Fax: (56) 2 339-7940
Japan
Ingersoll-Rand Japan,Ltd.
LS Bldg. 2F
1-1-17 Kami-Ohsaki
Shinagawa-ku, Tokyo
141-0020
Phone: +33-0130 07 6939
Fax: +33-0130 076980
Mexico
INGERSOLL-RAND, S.A. de C.V.
Blvd. Centro Industrial # 11.
Col. Industrial Puente de Vigas. 54070 Fax: (81) 3-5420-9116
Tlanepantla, Edo. de Mexico
Japan
Ingersoll-Rand Distribution Centre
Swan Lane
Hindley Green
Phone: (81) 3-5420-3392
Wigan
Mexico
Korea
Lancashire WN2 4EZ
England
Phone: +44 (0) 1942 257131
Fax: +44 (0) 1942 526255
Phone: (52) 8 503-6627
Fax: (52) 5 565-3072
Ingersoll-Rand T&H
#395-43, Seogyo-Dong, Mapo-Ku
Seoul, Korea 121-210
Phone: (82) 2 330 8090/1
Fax: (82) 2 31415893
Venezuela
Ingersoll-Rand Company
Centro Professional Eurobuilding
Piso 6 – Oficina 6-B
Chuao, Caracas
Phone: (58) 2 924-737
Fax: (58) 2 993-9276
8
P7648 Edition 1
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