Ingersoll Rand Remote Starter 150BMG User Manual

Form P6031  
03524832  
Edition 12  
January 2011  
Air and Gas Powered Starter  
Series 150BMG  
Installation and  
Maintenance Information  
Save These Instructions  
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causing corrosion and icing in cold weather. If either of these  
conditions exist, the starter will not operate. After all connections  
have been made, check each joint with a soap bubble test,  
7. Installation of a “glad handfor emergency repressurizing the  
system is recommended. To keep the “glad handclean and free  
of dirt, and to protect it from distortion, a second “glad hand”  
closed by a pipe plug can be mated to it, or a glad hand protector  
bracket can be used.  
Relay Valve Location  
Ingersoll-Rand recommends that the Relay Valve be mounted on the  
air tank. As an alternate location, the Relay Valve can be mounted  
on the starter. Mounting on the starter gives better control of the air  
supply closer to the point of use and provides more starts per tank  
of air. However, mounting on the starter adds overhung weight and  
subjects the air supply lines to dynamic pressure at all times.  
8. Whenever possible, always mount the starter so that the exhaust  
port is downward This will help prevent any accumulation of  
water in the starter motor.  
9. For increased protection during extended shelf life, the motor  
components of the starter have been coated with  
Ingersoll Rand No. 50 Oil. This oil will be dispersed during the first  
few cycles of the starter.  
* Registered Trademark of Loctite Corporation  
** Registered Trademark of Permabond Corporation  
Orientation of the Air Starter  
If the factory orientation will not fit your engine due to radial location  
of the Drive Housing or location of the inlet and/or exhaust ports,  
re-orient the starter as follows:  
NOTICE  
Make certain the connection is made to the inlet side of the Relay  
Valve indicated by the word ‘IN” cast on the valve body.  
1. Refer to the dimension illustration and note that the drive  
housing can be located in anyone of eighteen radial positions  
relative to the gear case. The exhaust port (motor housing) can  
be located in any one of four radial positions relative to the Gear  
Case, and the air inlet (Motor Housing Cover) can be located in  
any one of four radial positions relative to the exhaust port.  
2. Study the engine mounting requirements, and determine the  
required orientation of the Drive Housing relative to the Gear  
Case. If the Drive Housing has to be reoriented, remove the  
twelve Drive Housing Cap Screws and rotate the Drive Housing to  
its required position.  
5. Install the No. SMB-618 Starter Control Valve on the dash panel  
(for vehicular installations) or some other appropriate panel (for  
stationary installations).  
6. Attach No. TA-STR-100 Starter Instruction Label to the control  
panel adjacent to the Starter Control Valve.  
7. Mount the No. 150BMP-1064 Air Pressure Gauge on or adjacent  
to the control panel. It should be located where it is readily visible  
to the operator of the Control Valve.  
8. Connect the Starter Control Valve to the Relay Valve with 1/4”  
hose. Install a Tee in this line with a short feeder hose to the  
Pressure Gauge.  
NOTICE  
Do not separate the Drive Housing from the Gear Case Cover.  
Reinstall the Drive Housing Cap Screws and tighten them to 100 in-lb  
(11 Nm) of torque.  
NOTICE  
Make certain the hose is connected to the “SUPPLY” side of the  
Starter Control Valve.  
3. When orienting the Drive Housing relative to the Gear Case,  
determine if the exhaust port will be at the bottom and 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, and rotate the Motor Housing  
and/or Motor Housing Cover to its desired position.  
9. To determine the exact length of 1-1/4air hose required, run a  
piece of heavy-duty hose or some other flexible tubing of the  
same diameter from the Relay Valve on the receiver to the Starter  
location on the engine.  
10. Attach the 1-1/4air hose to the outlet side of the Relay Valve, and  
run the hose through the frame to its final position at the starter  
location.  
11. At this point, determine if 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.  
12. If possible, liberally grease the teeth on the ring gear with a  
good, sticky gear grease or motorcycle chain lube. This will help  
promote the life of the ring gear and the Starter Pinion.  
13. Place the starter into position, and mount it on the flywheel bell  
housing. Tighten the mounting bolts to 100 ft-lb (136 Nm) of  
torque.  
NOTICE  
Do not separate these members from each other or from the  
Gear Case. Reinstall the Motor Housing Cover Cap Screws and  
alternately tighten them to 25 ft-lb (34 Nm) of torque.  
Mounting the Air Starter  
1. Study the piping diagram Dwg. TPC585.  
2. The air receiver tank for a starter installation must meet  
SAE J10B specifications or conform to ASME specifications. It  
must have a working pressure capability equal to or greater than  
the maximum pressure at which the starter will be operated.  
3. When connecting the starter to a receiver tank that is already in  
service, bleed off the air pressure by opening the drain valve.  
14. If the exhaust is not to be piped away, install a No. 150BM-A674  
Muffler or No. 150BM-A735 Road Splash Deflector in the exhaust  
port on the Motor Housing of the Starter.  
15. Pressurize the complete starting system and check every  
connection with a soap bubble test. There must be no leaks.  
WARNING  
Bleed off the air pressure through a valve or petcock. Do not  
remove a plug from the tank while the tank is still pressurized.  
Drain off any water that has accumulated in the bottom of the  
tank.  
4. Using a 1-1/4short nipple, install the SRV125 Starter Relay Valve  
on the end of the receiver tank as shown in the piping diagram.  
Barring Over the Engine  
Occasionally, for setting injectors and/or for timing purposes, it may  
be desirable to bar over the engine in such a manner that any given  
piston can be stopped at any given location. This is very easily done  
with a 150BMG Starter.  
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1. Disconnect the 1/4hose at the “OUTport on the Drive Housing,  
and plug the hole in the Drive Housing with a 1/4pipe plug.  
2. Remove the 3/8pipe plug from the center of the Motor Housing  
Cover.  
3. Engage the Drive Pinion with the flywheel by applying a  
minimum of 70 psig (4.8 bar/483kPa) to the “INport on the Drive  
Housing.  
4. Insert a 5/16hexagonal wrench through the hole in the Motor  
Housing Cover to engage the hexagonal recess at the rear of the  
Rotor.  
5. Manually, rotate the Rotor until the engine is cranked to its  
desired position.  
Gas Operated Starters  
1. Apply a thin film of sealant to the Housing Cover End Plug and  
the Lubricator Port Plug as they are assembled.  
2. Plug the exhaust. Connect air line to the inlet, regulate the air  
pressure to 40 psig (2.8 bar/280 kPa) and immerse the unit for  
30 seconds in light oil, or non-flammable solvent. If there are  
any bubbles, the unit is unfit for gas operation. Tighten where  
necessary and/or apply sealant to area showing leak. Retest.  
WARNING  
When repairing a gas-operated starter or when converting a  
starter from air operation to gas operation, it is necessary to use  
Ingersoll-Rand No. MBA31 Plastic Gasket, as directed, and the  
following procedures for assembly and testing must be explicitly  
followed.  
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150BMG Series Air and Gas Starters Dimensional Drawing  
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150BMG Series Air and Gas Starters Typical Installation  
Starter control Valve  
SMB-G6618  
# 4 Hose (1/4”)  
Air Pressure Gage  
150BMP-1064L  
JIC 37˚ Adapter  
1/4 NPT  
Check Valve  
150BMP-1056  
JIC 37˚ Adapter  
1 1/2 NPT  
Air Supply  
Air  
Receiver  
Tank  
See Recommended  
Hose Size  
1 1/2NPT  
HDL3 Luricator  
Drain Valve  
150BMP-1067  
1/2 NPT  
Note:  
Use Seleant on all pipe connections.  
SMB-441  
For Gas Operation the exhaust outlet must be piped  
away to a safe location.  
Ingersoll Rand Part Number  
For Natural Gas Operation, Piped Exhaust must be  
used and Drive Housing vent plug replaced with  
suitable hose which connects into piped exhaust  
system.  
The performance of the Starter is dependent on the pressure at the inlet of the starter.  
This pressure is effected by the pressure drop between the Air Receiver Tank and the Starter.  
The most significant pressure drops will occur in fittings (Valves, Tees, Elbows, etc.)  
The next significant source of pressure drop is the hose. The following table provides  
recommended hose and Starter Relay Valves (SRV) sizes for typical one starter installations.  
Systems with many fittings or long hose should be analyzed and sized individually.  
For Air Applications a Muffler or Splash Guard  
Deflector must be used.  
(Dwg. TPC585)  
SRV Size  
Starter  
Hose Length  
Hose Size  
SRV 100  
SRV 100  
SRV 100  
SRV 125  
3BM, 5BM  
0-30’  
0-30’  
0-10’  
10-30’  
# 12 (3/4 “)  
SS175  
# 12 (3/4 “)  
# 16 (1 “)  
# 20 (1 1/4“)  
# 24 (1 1/2“)  
150BM/LF, SS350  
SS810, 815, 825, 850  
ST750, 799  
SRV 150  
0-50’  
Series 150BM and 150BMG Performance Curves  
25  
20  
15  
10  
5
1200  
900  
600  
300  
0
120  
100  
80  
60  
40  
20  
0
0
500  
1000  
1500  
Speed (RPM)  
2000  
2500  
3000  
(Dwg. TPC611)  
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150BMG Series Air and Gas Starters Sectional View  
(Dwg. TPA61-7)  
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150BMG Series Air and Gas Starters Exploded View  
(Dwg. TPA683-2)  
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150BMG Series Air and Gas Starters Parts List  
Part  
Number  
150BMP-A102A  
HSPPS3  
150BM-301  
R4K-302  
Item  
Part Description  
Item  
Part Description  
Part Number  
10BM-108  
1
2
*
Motor Housing Cover Assembly  
Housing Cover End Plug (3)  
Nameplate  
32 Drive Shaft  
for Model E22RH5-020  
for Models C21RH-6, C21LH-11,  
C21RH-16, C21RH-17,  
*
Nameplate Screw (3)  
10BM-8  
5
6
Motor Housing Cover Cap Screw (4)  
Cover Cap Screw Washer (4)  
107-25  
C21RH-31, C21LH-32, E21RH6-20  
E21LH11-020  
D02-504  
† 7 Motor Housing Cover Gasket  
† 8  
150LF-283  
‡ 33 Drive Shaft Collar  
10BM-30  
T02-33  
Rear Rotor Bearing  
R3H-24  
G57-729  
150LF-12A  
150BM-3  
10BM-98  
10BM-42-5  
10BM-40  
10BM-37  
10BM-25  
10BM-399  
R2-227  
† 34 Drive Shaft Front Bearing  
† 35 Rotor Pinion Retainer  
36 Rotor Pinion  
for “CModels  
for “EModels  
† 37 Front Rotor Bearing  
† 38 Gear Case Gasket  
39 Front End Plate  
40 Rotor  
† 9 Rear Rotor Bearing Retainer  
10 Rear End Plate  
11 Cylinder  
12 Cylinder Dowel  
† 13 Vane Packet (set of 5 Vanes)  
14 Motor Housing  
10BM-69  
101BMPD-17  
150BME-17  
10BM-24  
150LF-284  
150LF-11A  
10BMP-53  
K4U-A267AT  
K4U-286AT  
22SR-165  
15 Gear Case Assembly  
† 16  
† 18  
18A  
Bearing Ejecting Washer  
Drive Shaft Rear Bearing  
Plug  
# 51 Air Strainer Assembly  
52  
53  
54  
Air Strainer Cap  
Air Strainer Plug  
Air Strainer Screen  
19 Drive Gear  
for C models  
for E models  
10BMC-9  
150BME-9  
10BM-15  
10BM-610  
K4U-61AT  
55 Gasket (2)  
56 Gasket  
150BMP-283  
150BMP-284  
KKM-286  
9BM-B212-5/8  
9BM-B212-1  
10BM-CU212-1/2  
150BM-A735  
150BM-A674  
SMB-431  
† 19A  
Drive Gear Thrust Washer  
† 20 Drive Gear Key  
21 Gear Case Cover Assembly  
for Model C12RH-13  
*
*
*
*
*
*
*
*
*
Air Strainer Nipple (1-1/4x 2-1/2”)  
Mounting Adapter  
Mounting Adapter  
Mounting Adapter  
Road Splash Deflector Assembly  
Muffler Assembly  
Plastic Gasket  
Pipe Sealant  
Tune-up Kit  
10BM-378  
10BM-478  
150BMP-271  
---  
for all other models  
† 22 Drive Shaft Grease Seal  
23 Drive Housing Cap Screw  
Lock Washer (12)  
24 Drive Housing Cap Screw (12)  
27 Drive Housing Assembly  
10BM-67  
10BM-744  
9BM-A300-H2  
ML50K-318  
SM-441  
† ‡ 30  
Drive Housing Bearing  
(includes illustrated parts 7, 8, 9, 13,  
16, 18, 19A,20, 22, 30, 34, 35, 37,  
and 38)  
150BM-TK2  
‡ 31 Starter Drive  
for Models BM21RH-6 and BMG21RH-6  
for Models BM21LH-11 and BMG21LH-11  
for Models BM21RH-5 and BMG22RH-5  
10BM-299-21  
10BM-299-19  
10BM-299-22  
* Not Illustrated  
† Indicates Tune-up Kit part.  
‡ For every C model listed, there is a comparable E model. With the exception of the Drive Gear (19) and Rotor Pinion (36), comparable C and E  
models are identical.  
# Recommended on applications where air or gas could be contaminated.  
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Maintenance Section  
WARNING  
Always wear eye protection when operating or performing any maintenance on this Starter.  
Always turn off the air or Gas 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.  
Note: When reading the instructions, refer to exploded diagrams in parts Information Section when applicable.  
Lubrication  
Each time a Model 150BMG Starter is disassembled for  
maintenance or repair, lubricate the starter as follows:  
4. Wipe a thin film of Ingersoll Rand No. 130 Grease on the Drive  
Gear Thrust Washer (19A).  
5. Apply about 8 ounces of Ingersoll Rand No. 130 Grease to the  
assembled Drive Gear (19) and a uniform coat to the  
Drive Shaft (32) working the grease between all gear teeth,  
splines and bearing surfaces.  
1. Lubricate all open bearing and gear teeth with a liberal coat of  
Ingersoll Rand No. 130 Grease.  
2. Cover the bore of the Motor Housing Cover (1) with  
Ingersoll Rand No. 130 Grease.  
3. Apply a thin film of Ingersoll Rand No. 130 Grease to the Drive  
Shaft (32) and the bore of the Drive Shaft Front Bearing (34), Drive  
Shaft Collar (33) and Drive Gear (19).  
6. Wipe a thin film of Ingersoll Rand No. 130 Grease in the bore of  
the Drive Housing (27).  
Disassembly of the Starter  
General Instructions  
1. Do not disassemble the starter any further than necessary to  
replace worn or damaged parts.  
2. When grasping a part in a vise, always use leather covered or  
copper-covered vise jaws to protect the surface of the part and  
help prevent distortion. This is particularly true of threaded  
members.  
3. Do not remove any part which is a press fit in or on a  
subassembly unless the removal of that part is necessary for  
replacement or repairs.  
4. Always have a complete set of seals and O-rings on hand before  
starting any overhaul of a Model 150BMG Starter. Never reuse old  
seals or gaskets.  
5. Always mark adjacent parts on the Motor Housing Cover (1),  
Motor Housing (14), Gear Case (15) and Drive Housing (27) so  
these members can be located in the same relative position when  
the starter is reassembled.  
6. Never wash the Starter Drive (31) in a solvent.  
7. Do not press any needle bearing from a part unless you have a  
new needle bearing on hand for installation. Needle bearings are  
always damaged during the removal process.  
2. Remove the Drive Housing Cap Screws (24) and Drive Housing  
Cap Screw Lock Washers (23) and lift off the Drive Housing, Drive  
Gear and Starter Drive.  
3. Thread a 5/16”-18 thread cap screw into the tapped hole in the  
Bearing Ejecting Washer (16) and continue to turn it until the  
Drive Shaft Rear Bearing (18) is jacked from the Gear Case (15).  
Disassembly of the Drive Housing  
1. With the Drive Housing unit lying on the workbench, grasp the  
Drive Gear (19) and pull the assembled Drive Shaft (32) from the  
Starter Drive (31).  
2. If the Drive Gear must be removed from the Drive Shaft, support  
the Drive Gear on the table of an arbor press, and press the Drive  
Shaft from the Drive Gear. Remove the Drive Gear Key (20).  
3. Stand the Drive Shaft assembly, bearing end up, in a sleeve that  
contacts the Drive Shaft Collar (33), and press the Drive Shaft  
from the bore of the Drive Shaft Front Bearing (34).  
4. Position the Drive Housing (27) vertically, grasping the Gear Case  
Cover (21) in leather-covered or copper-covered vise jaws. Tap  
the underside of the drive housing mounting flange with a soft  
hammer to dislodge the Drive Housing from the Gear Case Cover.  
Lift off the Drive Housing. The Starter Drive will probably remain  
with the Drive Housing; make certain that it does not fall on the  
floor.  
Disassembly of the Motor  
1. Unscrew the Motor Housing Cover Cap Screws (5).  
2. Pull the Motor Housing Cover (1) from the Motor Housing (14).  
3. Slide the Motor Housing from the motor.  
NOTICE  
Do not remove the Drive Shaft Grease Seal (22) from the Gear  
Case Cover unless it is absolutely necessary and you have a new  
Seal on hand. If the Seal must be removed, press it from the Gear  
Case Cover.  
4. Grasp the rear end of the motor and pull the entire assembly  
away from the Gear Case (15).  
5. Position the motor assembly vertically, grasping the Rotor Pinion  
(36) in leather-covered or copper-covered vise jaws.  
6. Remove the Rear Rotor Bearing Retainer (9).  
7. The Rear Rotor Bearing (8) is press fit on the rotor shaft. Use a  
bearing puller to remove it.  
8. Lift off the Rear End Plate (10) and Cylinder (11) and remove the  
Vanes (13) from the slots in the Rotor.  
9. Reposition the Rotor vertically, pinion end up, and grasp the  
short hub in leather-covered or copper-covered vise jaws.  
10. Remove the Rotor Pinion Retainer (35) and lift off the  
Rotor Pinion (36).  
5. Do not remove the Drive Housing Bearing (30) from the Drive  
Housing unless you have a new Bushing on hand. If the Bearing  
must be removed, press it from the Drive Housing.  
Cleaning the Parts  
Once the Starter has been disassembled, clean all parts for  
inspection.  
1. Wipe all dirt, grease, etc. from the Starter Drive and sealed  
bearings.  
11. Support the Front End Plate (39) as close to the Rotor as possible,  
and press the Rotor from the Front Rotor Bearing (37). Do not let  
the Rotor fall when it is pressed free.  
NOTICE  
Do not wash these parts in kerosene or other solvent, as this will  
dilute and contaminate any sealed-in lifetime lubricant.  
2. Wash all parts except the Start Drive or any sealed bearing in  
clean kerosene or other solvent. Dry the parts with compressed  
air.  
Disassembly of the Gear Case  
1. Set the gear case and drive housing unit upright on the  
workbench with the Drive Housing (27) upward.  
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3. Check all needle bearings. Discard any needle bearing that was  
pressed from a parent member during disassembly of the starter.  
Remove and discard any other needle bearing that appears worn,  
distorted, has loose needles or does not run freely.  
4. Check all ball bearings. These should run freely without any rough  
spots or binding. Discard any bearing that gives any indication  
of wear. Check the Vanes for separation, chipping, wear, checks,  
etc. See that they fit freely in the vane slots in the Rotor. We  
recommend that a complete new set of Vanes be installed  
whenever the Starter is disassembled.  
Inspection of Parts  
1. Discard all O-rings and gaskets. These should not be reused.  
2. Check all grease seals. If they appear worn or distorted, remove  
them from their parent member and discard.  
NOTICE  
Discard any grease seal that was removed during disassembly  
of the starter.  
Assembly  
General Instructions  
Assembly of Motor  
1. Always press on the inner ring of a ball-type bearing when  
installing the bearing on a shaft.  
2. Always press on the outer ring of a ball-type bearing when  
pressing the bearing into a bearing recess.  
3. Whenever grasping a starter or part in a vise, always use  
leather-covered or copper-covered vise jaws. Take extra care with  
threaded parts or housings.  
4. Always clean every part and wipe every part with a thin film of  
Ingersoll Rand No. 50 Oil before installation.  
5. Check every bearing for roughness. If an open bearing must  
be cleaned, wash it thoroughly in a clean, suitable, cleaning  
solution and dry with a clean cloth. Sealed or shielded bearings  
should never be cleaned. Work Ingersoll Rand No. 130 Grease  
thoroughly into every open bearing before installation.  
6. Apply a film of o-ring lubricant to all o-rings before final  
assembly.  
7. Lubricate all open bearing and gear teeth with a liberal coat of  
Ingersoll Rand No. 130 Grease. Lubricate Starter Drive Housing  
Bearing (30) and gear teeth with a liberal coat of Ingersoll Rand  
No. 130 Grease. Work about 3 cc into the teeth of the Drive Gear.  
8. Lubricate the Gear Case and Gear Case components with  
Ingersoll Rand No. 130 Grease.  
1. Position the Rotor (40) vertically, splined end down.  
2. Place the Rear End Plate (10), crescent grooved side first, onto the  
hub of the Rotor.  
NOTICE  
Make sure that all notches and ports are in alignment.  
Refer to Dwg. TPA683-2.  
3. Install the Rear Rotor Bearing (8) onto the hub of the Rotor until it  
contacts the Rear End Plate. Make certain the End Plate does not  
bind against the Rotor.  
4. Install the Rear Rotor Bearing Retainer (9) in the groove on the  
hub of the Rotor.  
5. Grasp the Motor Housing Cover (1), motor bore face upward,  
in copper-covered or leather-covered vise jaws. Swivel the vise  
so that the air inlet is facing you. Cover the bore of the bearing  
recess with a thin film of Ingersoll Rand No. 130 Grease.  
6. Check the nameplate on the Starter to determine whether you  
have an “LHmodel or “RHmodel.  
For “LH” models: While facing the air inlet on the Motor Housing  
Cover, insert the Cylinder Dowel (12) in the dowel hole on the  
right of the inlet.  
9. When assembling the motor always use new O-rings.  
10. Before installing O-rings, coat liberally with O-ring lubricant. After  
the O-ring is installed, coat the O-ring again with o-ring lubricant  
and apply O-ring lubricant to O-ring grooves.  
For “RH” models: While facing the air inlet on the Motor Housing  
Cover, insert the Cylinder Dowel (12) in the dowel hole on the left  
of the inlet.  
11. The Cylinder Dowel (12) maintains the alignment of the Motor  
Housing Cover (1), Front End Plate (39), Cylinder (11) and Rear  
End Plate (10). The end of the Dowel fits into a shallow hole in the  
face of the Motor Housing Cover. It is important that the end of  
the Dowel is in the hole and remains there during assembly.  
12. Unless otherwise noted, always press on the stamped end of a  
needle bearing when installing the needle bearing in a recess.  
Use a bearing inserting tool similar to the one shown in  
Dwg. TPD786.  
NOTICE  
Make certain the Cylinder Dowel is installed in the proper dowel  
hole. If you put it in the wrong dowel hole, the motor will rotate  
in the wrong direction.  
7. Place the Motor Housing Gasket (7) in the bore of the Motor  
Housing Cover.  
NOTICE  
Make sure that the Motor Housing Gasket is installed with the  
Cylinder Dowel hole positioned upward and properly oriented  
relative to the Cylinder Dowel. The Cylinder Dowel hole in the  
Gasket is the hole which is centered between the two angled  
ports in the Gasket. Refer to Dwg. TPA683-2.  
Needle Bearing inserting Tool  
8. Place the assembled End Plate and Rotor into the Motor Housing  
Cover that the Cylinder Dowel passes through the dowel hole in  
the End Plate, and so that the air port in the End Plate aligns with  
the port in the Gasket and Motor Housing Cover.  
9. Place the Cylinder (11) down over the Rotor so that the Cylinder  
Dowel passes through the dowel hole in the Cylinder and so that  
the air port in the Cylinder is aligned with the air port in the Rear  
End Plate, Gasket, and Motor Housing Cover.  
10. Place the Motor Housing (14) down over the Cylinder making  
certain that the prick punch marks on the Motor Housing Cover  
and Motor Housing are aligned.  
11. Liberally coat each Vane (13) with Ingersoll Rand No. 50 Oil and  
insert a Vane into each slot in the Rotor. Make certain the straight  
edge of each Vane faces the Cylinder.  
15°  
Shoulder to  
Regulate Depth  
Pilot to fit I.D. of Bearing.  
Length of Pilot to be  
approximately 1/8less than  
length of Bearing  
(Dwg. TPD786)  
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12. Set the Front End Plate (39), crescent grooved side first, onto the  
Cylinder so that the Cylinder Dowel passes through the dowel  
hole in the End Plate. Make sure that all notches and ports are in  
alignment.  
13. Install the Front Rotor Bearing (37) onto the splined shaft of the  
Rotor until it seats against the Front End Plate. Do not bind the  
End Plate against the Rotor.  
14. Slide the Rotor Pinion (36) onto the rotor shaft.  
15. Install the Rotor Pinion Retainer (35) in the groove on the rotor  
shaft so that the concave side of the Retainer faces the Rotor  
Pinion.  
4. Wipe a thin film Ingersoll Rand No. 130 Grease on the Drive  
Gear Thrust Washer (19A), and place the Washer on the lip of the  
bearing recess in the Gear Case.  
5. Apply about 8 ounces of Ingersoll Rand No. 130 Grease to the  
assembled Drive Gear (19) and a uniform coat of  
Ingersoll Rand No. 130 Grease to the Drive Shaft (32), making  
certain to work the grease between all the gear teeth, splines and  
bearing surfaces.  
6. Insert the assembled Drive Gear and Shaft, short hub end first,  
into the Gear Case so that the short hub enters the Drive Rear  
Bearing.  
16. Apply a light coat of Ingersoll Rand No. 130 Grease to the Gear  
Case Gasket (38) and place the Gasket in the motor bore of the  
Gear Case.  
17. Set the Gear Case on the assembled motor, making certain the  
prick punch marks on the Gear Case are aligned with those on  
the Motor Housing.  
18. Turn the entire assembly over so that the Motor Housing Cover is  
upward. Make sure that the Cylinder Dowel remains seated in the  
shallow hole in the face of the Motor Housing Cover.  
19. Install the Motor Housing Cover Cap Screws (5) and Lock Washers  
(6). Tighten the Cap Screws alternately to 25 ft-lb (34 Nm) of  
torque.  
7. Slide the assembled Gear Case Cover, bearing recess first, down  
over the Drive Shaft until it seats against the Gear Case.  
NOTICE  
Check the inner lip of the Drive Shaft Grease Seal to make certain  
that it did not fold outward toward the end of the Drive Shaft. If  
it did fold outward, you must reinstall the Gear Case Cover using  
a fine pointed instrument to roll the lip of the seal the proper  
direction.  
Assembly of Drive Housing  
1. If the Drive Housing Bearing (30) was removed, stand the Drive  
Housing (27) upright and press a new Drive Housing Bearing,  
unstamped end first, into the Drive Housing until the unstamped  
end of the Bearing is flush with the inside face of the Drive  
Housing boss. Work some Ingersoll Rand No. 130 Grease in the  
Bearing.  
Assembly of Drive Gear  
1. If the Drive Shaft Grease Seal (22) was removed from the Gear  
Case Cover (21), press in a new Seal so that the inner lips of the  
Seal face the bearing recess for the Drive Shaft Front Bearing (34).  
2. Apply a thin film of Ingersoll Rand No. 130 Grease to the Drive  
Shaft (32) and the bore of the Drive Shaft Front Bearing, Drive  
Shaft Collar (34), and Drive Gear (19).  
NOTICE  
Do not clean the Starter Drive (31) with solvent. If Starter Drive  
appears dry, apply Ingersoll Rand No. 130 Grease to the threads  
under the pinion.  
2. Apply a thin film of Ingersoll Rand No. 130 Grease to the surface  
of the Drive Shaft (32).  
3. Press the Drive Shaft Collar, beveled end first, onto the keyway  
end of the Drive Shaft until it seats against the shoulder of the  
shaft.  
4. Press the Drive Shaft Front Bearing onto the keyway end of the  
Drive Shaft until it seats against the Drive Shaft Collar. Pack the  
Bearing with Ingersoll Rand No. 130 Grease.  
3. Place the Starter Drive on the Drive Shaft.  
4. Place the Drive Housing over the Drive onto the Gear Case Cover  
(21). Rotate the Drive Housing into the required orientation as  
indicated by the punch marks. At the same time, align the Cap  
Screw holes in the Gear Case Cover and Housing.  
5. Install the Drive Housing Cap Screws (23) and Lock Washers (24)  
and tighten the Cap Screws to 100 in-lb (11 Nm) of torque.  
5. Install the Drive Gear Key (20) in the keyway on the Drive Shaft.  
6. Press the Drive Gear (19), long hub first, on the Drive Shaft until it  
contacts the Drive Shaft Front Bearing.  
Assembly of Gear Case  
1. Set the assembled motor and Gear Case (15) on end with the  
Gear Case upward.  
2. Place the Bearing Ejecting Washer (16) in the bearing recess.  
3. Using a needle bearing inserting tool, press the Drive Shaft  
Rear Bearing (18), unstamped end first, into the bearing recess  
until the trailing face of the Bearing is flush with the face of the  
bearing recess. Refer to Dwg. TPD786.  
Work some Ingersoll Rand No. 130 Grease between the-rollers of  
the Bearing.  
Testing the Starter  
1. Turn the pinion by hand in the direction of Starter rotation. The  
pinion should advance smoothly and easily to the stop.  
2. Turn the pinion opposite the direction of Starter rotation. The  
gearing and motor should rotate freely with no binding.  
3. Attach an air hose to the inlet and operate the motor slowly to  
see that it functions properly and that the drive pinion rotates in  
the proper direction. If the direction of rotation is incorrect, the  
motor was improperly assembled.  
4. The chambers on the pinion teeth should be on the following  
side of the teeth.  
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Troubleshooting Guide  
Trouble  
Probable Cause  
Solution  
No air supply  
Damaged motor assembly  
Check for blockage or damage to air supply lines or tank.  
Inspect Motor Assembly and power train and repair or replace if necessary.  
Foreign material in motor and/or piping Remove Motor Assembly and/or piping and remove blockage.  
Blocked exhaust system  
Remove Housing Exhaust Cover (1) and check for blockage.  
Replace Control Valve or Relay Valve.  
Motor will not  
run  
Defective Control Valve or Relay Valve  
Low air pressure to Starter  
Restricted air supply line.  
Relay Valve malfunctioning  
Exhaust flow restricted  
Check air supply.  
Check for blockage or damage to air lines.  
Clean or replace lines or Relay Valve. Lube Relay Valve.  
Check for blocked or damaged piping. Clean or replace piping. Check for dirt  
or foreign material and clean or remove. Check for ice build-up. Melt ice and  
reduce moisture build-up to Starter.  
Worn motor parts  
Remove the motor from the Motor Housing (14) and disassemble the  
motor. Examine all parts and replace any that are worn or damaged. Use the  
following guidelines for determining unserviceable parts:  
1. Vanes (13): Install a new set of Vanes if any Vane is cracked, checked or  
worn.  
Loss of Power  
2. Rotor Bearings (8) or (37): Replace if any roughness or looseness is  
apparent.  
3. Rotor (40): Replace if there are any cracks or deep scoring.  
4. Cylinder (11): Replace if there are any cracks or deep scoring.  
5. End Plates (10) or (39): Clean up scoring by rubbing it with emery cloth  
placed on a flat surface.  
Lack of air to starter  
Check for clogged or damaged air line between relay valve and starter.  
Check relay valve to determine if it is functioning properly. Check air tank.  
Parts and Maintenance  
NOTICE  
The use of other than genuine Ingersoll Rand replacement parts may result in safety hazards, decreased starter performance, and increased  
maintenance, and may invalidate all warranties.  
Ingersoll Rand is not responsible for customer modification of starters for applications on which Ingersoll Rand was not consulted.  
Repairs should be made only by authorized trained personnel. Consult your nearest Ingersoll Rand Authorized Service center.  
When the life of the tool has expired, it is recommended that the starter be disassembled, degreased and parts be separated by material so that  
they can be recycled.  
Refer all communications to the nearest Ingersoll Rand Office or Distributor.  
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Notes:  
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© 2011 Ingersoll Rand  
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