..

:
1,/ -, ~ Do not install, operate or perform maintenance on this Starter
.I,
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before reading this Installation and Maintenance Manual.
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1
INSTALLATION AND MAINTENt~NCE MANUAL
I
~).
for
I

1 SERIES ST700 TURBINE-POWEFtED STARTERS

FOR TOP PERFORMANCE AND MAXIMUM DURABILITY OF PARTS, DO NOT OPERATE SERIES ST700
START2US AT AIR PR::SSUr:ES OVER THE PRESSURE RATING STAMPED ON THE NAMEPLATE. USE
SUPPLY LINES OF ADEQUATE SIZE AS DIRECTED IN THE INSTALLATI N INSTRUCTIONS IN THIS
MANlJAL.

I M10limllm
I
Series ST700 Starters are designedI for gas operation. They arc not totally sealed in dynamic operatlon since the exhaust
must be vented or piped away and there is a possibility of leakage around the output shaft when rotating.
!
,1

11 Caution should be taken when operating these Starters on gas because of the danger of fire, explosion, or inhalation.
'1 After reassembling a Series 51700 Starter, always test it in accordance with the procedures outlined in this manual. Never
·1 install ~ re;,;,::::::::mbledStarter that has not been tested in accordance with the procedures outlined in this manual.
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Operate Starter only when properly installed on engine.

i:-iUN , _ e 3 ,-:'4 ~ .•. '

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1J The use of other than genuine Ingersoll-Rand replacement parts may result in decreased Starter performance and increased
maintenance, and may invalidate aU warranties.

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Ingersoll-Rand Ot::.:::eor Distributor. Ii ®

J (9Ingersoll-Rz::!:': ::.~~-_iY 1991

Printed in U.2.i, ENGINE STARTING SYSTEMS.
1 ,

••
 INSTALLATION
~ For maximum performance, read t:lis manual
Turbine-Powered Starters,
( 11
General Information
1. It is strongly recommend that on all vehicular installations
and on stationary engines subject to vibration, that hoses of the
specified diameter be used instead of rigid pipe connections to
the S tarter. Vehicle and engine vibration will soon loosen rigid
pipe connections, whereas hoses will absorb the vibration, and
connections will remain tight
2. This Starter is designed for flange mounting at the inlet. The
furnished Flange Mounting Kit is required for installation. All
piping, hoses and valving must be clean prior to installation.
Make sure that the Starter inlet remains free of dirt and foreign
material during installation.
3. In the actual mounting of a Starter, it may be best to have the
hose connections already made at the receiver and to have the
I
Starter end of the hose handy for attaching to the Starter.
4. Engine design often demands that the Starter be mounted un-
derneath in extremely ciose 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 re-
quired: regular ratchet wrench, sockets, universal joint, socket
extension and a single or double-end box wrench.
5. Theefficiencyofan Air Starter can be greatly impaired by an
(\.../\1 improper hook-up. Hoses smaller than those recommended
will reduce the volume of air to the motor and the use of reduc-
ers for piped-away applications in the exhaust port will restrict,
the exhaust causing back pressure to the motor resulting ih re-
duced performance. The number of Tees and elbows! and th_e
length of the supply line should be kept to a minimum. U~
1-1/2" hose or pipe for supply lines up to 15 feet long; use 2"
hose or pipe if the supply line is over15j~t lex·;g:
6. A leak in any of the connections in live air lines means that
the system will drain overnight and will have to be re-pressu-
rized the next morning by use of another vehicle or compressor.
Make your connections bubble tight to avoid unnecessary
costs and delays.
On all threaded connections throughout the system, use
Ingersoll-Rand No, 5MB--441 Sealant, non-hardening No.2
Permatex or Loctite®* Pipe Sealant,
Always run the air supply line from the side or top of the
receiver, never at or near the bottom. Moisture in the air col-
lects 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.
(J *Registered trademark of Loctite Corporation
prior to the installation or operation of Series ST700
Mounting the Air Starter
1. Study the appropriate piping diagrams on pages 7,8,9 and 10
and install as indicated.
2. Toe air receiver tank for a Starter installation must have a
working pressure rating equal to or greater than the maximum
pressure at which the Starter will be operated.
3. When connecting the Starter to a receiver tank that is already
in service, bleed off the air pressure in the tank prior to install-
ing the Starter,
~
.Bleed off the air pressure through a valve or petcock, Do
not remove a plug from the tank while the tank is still
pressured.
Drain off any water that may have accumulated in the bottom
of the-tank,
4. Using a 1-1(2" short nipple, install the SRV 150 Starter
Relay Valve on the end of the receiver tank as shown in the
piping diagram.
Make certain the connection is made to the inlet side of the
Relay Valve indicated by the word "IN", cast on the valve
body.
5. For air installations, install the Starter Control Valve
(S~18) 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 12V
Solenoid Valve (l50BMP-I05 IB) securely and preferably ina
vertical position away from any concentration of heat, vibra-
tion or contamination. Connect the leads to the operator's start-
ing swi tch which should be located on the dashboard or control
panel.
6. Attach Starter Instruction Label (TA-S1R-lOO) to the
control panel adjacent to the Starter Control Valve.
7. Mount the Air Pressure Gauge (150BMP-I064) on or adja-
cent to the control panel. It should be located where it is readily
visible to the operator.
8. Connect the Starter Control Valve to the Relay Valve with
1/4" hose. Install a Tee in this line with a short feeder hose to
the Pressure Gauge.
Make certain the hose is connected to the supply
(marked "SUP") of the Starter Control Valve.
side
11
 , ~ ,.,-
9. To determine the exact length of 1-1/2" air hose required,
run a piece of heavy duty hose or some other flexible tubing of
.,- the same diameter from the Relay Valve on the receiver to the
Starter location on the engine.
,1 10. Attach the 1-1/2" air hose to the outlet side of the Relay
Valve, and run the hose through the frame, etc. to its final
position at the Starter location,
11. At this point, de term ine whether or not it is feasible or prac-
tical to attach the hose to the S tarter 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.Iiberally 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 V..e Starter Pinion.
13. Move the Starter into position, and mount it on the flywheel
housing. Tighten the mounting bolts to 100 ft-lb (136 Nm)
torque.
14. For Pre-Engaged Mooel.s, install a 1/4" hose line from
the delivery side (marked "DEL") of be Starter Control Valve
i ented for installation, proceed as follows:
or Solenoid Valve to the "IN" port on the Starter Drive
Housing.
Inadvertent application of air pressure to the "OUT' port
win result in Drive malfunction (pinion will fail to retract).
II this condition occurs, loosen Drive Housing Cap Screws
(38) to vent Gear Case (28). Also, loosen Housing Plugs (10)
and (11) to .vent Motor. ~
15. Install a 1/4" hose line from the "OUT" port on the Starter
Drive Housing to the small pipe tapped portion top of the
Starter Relay Valve or Solenoid Valve.
16. If the exhaust is to be piped away, remove the standard
Splash Deflector which is located at the rear of the Housing
. Exhaust Cover and replace the Assembly with the 1/4" N.P.T.
pipe plug supplied with the Starter.
17. Pressurize the complete starting system and check every
connection with a soap bubble test There must be no leaks in
live air lines or other connection.
Barring Over the Engine
Occasionally, [or 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 Series STIOO Turbine Starter.
1. Remove the Deflector Retaining Screw (5), the Deflector
Return Spring (4) and the Splash Deflector (3). If piped-away
exhaust is being used, remove piping so that you can gain
12
access to the hole at the center of the Housing Exhaust Cover.
•...ernove the 1/4" pipe plug.
After all connections have been made, check each joint with a
soap bubble test, There must be no leaks in live air lines. The
slightest leak will cause the system to lose pressure overnight
7. Whenever a hazardous gas is being used to operate the
Starter, there must be no leaks in inlet or exhaust piping or
from any other Starter joints. All discharges should be
piped away to a safe area.
8. We recommend installation of a "glad hand" for emergency
re-pressurizing of the system. To keep the "glad hand" clean
and free of dirt, and to protect it from damage, a second "glad
hand" closed by apipe plug can be mated to it.or a "glad hand"
protector bracket can be used.
Orientation of the Starter
It is recommended that Starters be ordered to proper orienta-
tion for your specific mounting to the required engine or fer
your specific installation. However, if the Starter must be reori-
A. Refer to the dimension illustration on pages 4, 5 and 6 and
note that the Drive Housing can be located in anyone of six-
teen radial positions relative to the Gear Case and the air in
let can be located in anyone of four radial positions relati ve
to the Drive Housing.
B. 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 and rotate the
Drive Housing to its required position. Separation of the
Drive Housing from the Gear Case is not required. Reinstall
theDrive Housing Cap Screws and tighten to' 28 ft-Ib
(38 Nm) torque.
C. After the Drive Housing is properly oriented relative to the
Gear Case, determine if the inlet port will be favorably
located for hose installation. If either or both of these
members must be reoriented, use an 8 mm hex-head wrench
to remove the four motor housing cover cap screws, and
rotate the motor housing and/or motor housing cover to its
desired position.
Do not separate the Motor Housing from the Intermediate
Gear case as gear lubrication oil will be lost.
Reinstall the motor housing cover cap screws and altemate-
ly tighten them to 60 ft-lb (81.4 Nm) torque in 20 ft-lb (l.7
Nm) increments.
 .e,
.,

for Models For Models

(1 ST750GSDiC3R3~ , ST75UGBDP03R31, S1750GBDP03L32,
ST750G8D!03L32, ST7SOGCDP03R25, ST750GCDP03L26,
ST799GBDi03R31 and ST750GDDP09R51, STISOGDDP09L52,
S1799G B D !C3L32: S1799GBDP03R31, ST799GBDP03L32,
ST799GCDP03R25, ST799GCDP03L26,
(2) M...anually engage pinion and insert a 1/4" hex wrench ST799GDDP09R51 and ST799GDDP09l52:
through the hole in the Housing Cover to engage the hex
drive recess at the rea: o[ ~e Mo:cr Assembly. (a) Disconnect the 1/4" hose at the "OUT" port on the Drive
(b) t~-:ually rotate C:e ~,/I01Or Assembly until the engine is Housing, and plug the hole in the Drive Housing with a
cranked to the desired ?Jsit~C)n. 1/4" pipe plug.
(b) Engage the Drive Pinion with the flywheel by applying
a minimum of 70 psig (4.8 bar/483 kPa) to the "IN" port
on the Drive Housing.
(c) Insert a 1/4" hex wrench through the hole in the Housing
Exhaust Cover to engage L.'J.ehex drive recess in the rear of
the Motor Assembly.
(d) Manually rotate the Motor Assembly until the engine is
cranked to the desired position.

( a
'-

.'

l§
13
 DISASSEMBLY OF THE STARTER
Ceneral Information 4. Remove the Deflector Retaining Screw (5). Deflector
1. Always mark adjacent parts on the Housing Exhaust Cover Retaining Spring (4) and the Splash Deflector (3) from the
(1). MOI.Or Housing (8). Intermediate Gear Case (13). Gear Housing Exhaust Cover.
Case (28) and Drive Housing (38) so these members can be
:~ located in the same relative position when the Starter is
reassembled.
...:.I.
,
2. Do not disassemble the Starter any further than neces-
l sary to replace worn or damaged parts.
,
~ 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
1 replacement or repairs. 5
4. Always have a complete set of seals and O-rings on hand
1
~1
I
before starting any overhaul of a Series snoo Turbine Starter.
Never reuse old seals or O-rings. I
5. When grasping a part in a vise, always use copper-covered
J vise jaws to protect the surface of the part and help prevent dis-

1 ,i
tortion. This is particularly true of threaded members.
6. Neyer wash the Inertia Drive in a solvent.
• I
Housing Exhaust Cover, Motor t\.ssembly, and Motor
I

Housing. .
1. If replacing the Motor Assembly (12), remove both Housing
Plugs (10) and drain the oil from the gearing before beginning
disassembly of the Starter.Inspect the Magnetic Housing Plugs (Dwg. TPD1160)
(10) for metal particles. Very fine meta! particles are normal.
Remove particles and reirlstall plugs. Large particles or chips
are an indication of a problem. Disassemble Gear Case (28) S. Tap the Motor Housing with a plastic hammer to dislodge it
and inspect, ~

II
from the Intermediate Gear Case (13). ~.

2. Using an 8 mm hex-head wrench, unscrew and remove the

Starter Assembly Cap Screws (6) and Washers (7).
3. Pull !he Housing Exhaust Cover (1) from the Motor Housing
(8). To dislodge the Housing Exhaust Cover. rotate it until the
• ears clear the Motor Housing. Using a plastic hammer. tap the

I
ears alternately until the Housing Exhaust Cover can be re- 8
13
moved from the Motor Housing.
7
1
j

PLASTIC HAU),iER

(Dwg. TPD1162)

,
6. Grasp the rear of the Motor Assembly (12) and pull it from
(Dwg. TPD1159) the rear of the Motor Housing. ~

14
 • r'

If the Motor Assembly is difficult to remove, lightly push the Tap the Intermediate Pinion lightly to back the Planet Gear
motor pinion which is on the front of the MOtGi Assembly Frame Assembly cut of the Intermediate Gear Case.
toward the exhaust side of the Motor Housing in order to free
the Motor Assembly.
(It

12A

(Owg. TPD1169)
10. Remove the Intermediate Gear Case Assembly from the
(Ow;;. TP01161) vise and remove the Intermediate Pinion. Remove the Rear
7. Tap the Intermediate Gear Case with a plastic hammer to Gear Case O-ring (14) and Front Gear Case O-ring (15) from
dislodge it from the Gear Case (28). the Intermediate Gear Case.
11. Remove the Planet Gear F "",meAssembly from the Inter-
mediate Gear Case. Using a sleeve that contacts the outer race
of the Front Gear Frame Bearing (17), press the Planet Gear
Frame Shaft Seal (16) and the Front Gear Frame Bearing (17)
from the front end and out of the rear of the Intermediate Gear
( :~ Case.

PlAST! C HAlA'ER
..,

(Dwg. TPDl164)
8. Position the Intermediate Gear Case on a bench in a copper-
faced vise so that the Intermediate Pinion (26) is secured in the
jaws of the vise. Tighten the vise only enough to hold the Inter-
mediate Pinion securely.
9. Loosen the Intermediate Pinion Retaining Screw (27)
1-;1/2 turns only. Do not remove.
.-.
If the Intermediate Gear Case is not supported on a bench
and if the Intermediate Pinion Retaining Screw is com-
pletely removed, the Intermediate Gear Case and compo-
./ nents could fall causing injury .
PLANET GEAR FRAME ASSEMBLY
(Dwg. TPD1166)
12. Using a bearing puller, remove the Rear Gear Frame
Bearing (24) from the Planet Gear Frame (18) and remove the
Gear Shaft Retaining Washer (23).
13. Remove the Planet Gear Shafts (22), Planet Gears (19),
Planet Gear Bearings (20) and Bearing Spacers (21).
14. Using a bearing puller, remove the Front Bearing Spacer
(25) and the Gear Shaft Retaining Washer (23) from the front

15
 i'.~ . .' /
a; l..'1ePlanet Gear Frame by pressing on the front of the Planet 6. Remove the two Drive Gear Keys (37) from the Drive
Gear Frame Shaft Gear Shaft.
Remove the Gear Shaft Retaining Washer only if the
Washer or Front Bearing Spacer is damaged.

2119

. 20
Ii , _21
~
22
\
\

24

\ 23
25 )

(Dwg. TPD1171)

Dwg. TPD1167) 7. Remove the Gear Case Cover from the Gear Case.
8. Remove the Drive Housing O-ring (35) and the Gear Case
J\ Drive Housing Inertia Models
Cover Seal (33) from the Gear Case Cover.
Il
,~ For Models ST750QBDI03R31, ST750GBDI03L32,
9. Pull the Drive Gear (30) out of the Gear Case.
ST799GBDI03R31 and STI99GBDI03L32: ;
10. Remove the Rear Drive Gear Bearing (31) and the Front
1. Remove the eight Drive Housing Cap Screws (40) and Lock
Washers (41). Drive Gear Bearing (30) from the Drive Gear.
2. Tap the Drive Housing (38) with a plastic hammer to help Pre-Engaged Models
dislodge it from the Gear Case Cover (32). Remove the Drive For Models ST750GBDP03R31, ST750GBDP03L32,
Housing (38) from the Starter Drive (36). ST750GCDP03R25, ST750GCDP03L26,
ST750GDDP09R51, ST750GDDP09L52,
ST799GBDP03R31, ST799GBDP03L32,
ST799GCDP03R25, S1799GCDP03L26,
ST799GDDP09R51 and ST799GDDP09L52:
~41 __
(Refer to illustration on page 30)
~40
1. Grasp the Drive Pinion (63) in a copper-faced vise with the
Starter supported on the workbench.
2. Remove the Drive Pinion Retaining Screw (61).

Models ending in R25, R31 and R51 have a left-hand

thread. I
Models ending in L26, L32 and L52 have a right-hand
thread.
3. Remove the Starter from the vise.
4. Remove the Drive Pinion Washer (62) and the Drive
Pinion.
5. Slide the Pinion Spring Sleeve (64) and the Pinion Spring
(Dwg. TPD1168) (65) off the Drive Shaft,
3. Place the Drive Housing in an arbor press, bearing end up. 6. Using an impact wrench with a 5/16" (8 mm) x 8" (203 mm)
Using a pressing bar remove the Drive Housing Bearing (39) long hex inserted into the end of the Drive Shaft, unscrew the
from the Starter Drive Housing. Drive Gear Screw (34).
4. Using a screwdriver, displace the locking spring and re- 7. Unscrew and remove the Drive Housing Cap Screws (38)
move the screw holding the Starter Drive (36) to the Drive Gear and Lock Washers (37).
Shaft. 8. Tap the Drive Housing (40) with a plastic hammer 10 heJp
5. Slide the Starter Drive off the Drive Gear Shaft. dislodge it from the Gear Case (28).

16

l
 • I
.. 22. Press the Rear Drive S'lailBearing and Drive Shaft(57)out
0: Lle Piston. d the Real Drive Shaft Bearing needs to be re-
Fa.lure to fellow ~his procedure could result in injury ({J placed, proceed as follows:
personnel. a. Using a small chisel, cut and remove the small drive
~l 9. Place the Drive Housing :0 an arbor press, piston end up. shaft bearing retained in the Drive Shaft.
Apply c. road :.0 the Piston (5~) using the arbor press to com- b. Press the Rear Drive Shaft Bearing (58) off the Drive
press the Piston Retur.: S~rir.3(59) before removing the Bulk- Shaft.
head Retainer (45). Do net u..::~co.npresze.; air to load the ie Gear Case (28) on a workbench.
23. Place t••..
~isto:-!. 24. Using retaining ring pliers and working through the access
10. Using <.. screwdriver, remove t1.:;Bulkhead Retainer. Use holes in the gear web, remove the Drive Gear Bearing Retainer
cfI tte arbor press. (32).

I I·.1a~-c::'_,e the 1en:;ic:: d ::::: s~, :r.g ~H15:.e::; the Bulkhead

I Gut of:112 Drive Housing :::::(:;u; L:!::wYing the Drive Hous-

lng from the arbor press.
11. Remove Lie Bulkhead (45) from Lie Piston.
32
12. Remove the Outer Bulkhead Ring (47) and the Inner Bulk-
head Ring (48).
13. Slide the Drive Shaft q7) from the Drive Housing.
4. Pull the Piston Return Spring (59) off the Drive Shaft,

28

Do act remove the Front :;rin Shaft Bearing (42) or the

Drive 2-Ioi15:ng Seal (43) u.iless replacement is necessary
:ay and new parts are available. The Bearing and/or the Seal
will always be damaged when removed from the Drive
Housing.
15. Remove the Piston Ring (55) from the Piston.
16. Insert a large screwdriver clade through the Piston Seal
(56) so thatit rests on tcp of the Clutch Spring Cup (50). Pry the
Seal c :~of the Piston.

(Dwg. TPD1170)
This operation will damage c;le Piston Seal. Therefore, a
25. Pull the Drive Gear (29) out of the Gear Case.
replacement Piston S~I ~r,w~ be on hand,
17. Press the Clutch Spring CLiP (50) down and remove the
Clutch Spring Cup Retainer (49). Do not disassemble the Drive Gear and Clutch parts of
18. Remove the Clutch Spring Cup and Clutch Spring (51). Series ST700 Turbine-Powered Starters. If the Drive
19. Remove the two Clutch Jaws (52). Shaft is defective, install a new or factory-rebuilt unit.
20. Remove the Front Drive Gear' Bearing (30), Drive Gear
Cup (46), Drive Gear Leek Washdr (35), Drive Gear Screw 26. Using retaining ring pliers, remove the Drive Gear Shaft
Ring (37) and Drive Gear Screv (34). Bearing Retainer (33).
21. Using a screwdriver, remove the large Drive Shaft Bearing 27. Remove the Rear Drive Gear Bearing (31) from the Drive
Retainer (53). Gear.

( \
\

17

~-------------------------------------
.,
ASSEl'vlBLY
General lnformatio
1. Always press on the inner ring of a ball bearing when
installing the bearing on a shaft.
2. Always press on the outer ring of a ball bearing when
pressing the bearing in a bearing recess.
3. Whenever grasping a part in a vise, always use leather-
covered, copper-covered vise jaws to protect the surface of the
part and help prevent distortion. This1is particularly true of
threaded members.
4. Always clean every part, and wipe every part with a thin
film of oil before installation.
OF TIlE STAlrnm
Drive Houslng
8. Slide the Starter Drive (36) onto the drive gear shaft and
tighten the Starter drive locating ring and screw securely.
9. , less the Drive Housing Bearing (39) into the Drive Housing
(38) and lubricate with the recommended lubricant.
See illustration below.
o

On modeis with Inertia Drive, do not lubricate threaded

area of the Driv _ Shaft as it could collect dirt and foreign
material which will hinder efficient operation.
Inertia Drive
For Models ST750GBIDI03R31, ST750GBDIO~L32,
-----;.1
ST799GBDI03R31 and ST799GBDI03L32:
~ PILOT TO FIT 1.0. OF BEARING.
LENGTH if P ILOT TO BE
Gear Case APPROXIMATELY I/S- LESS THAN
1. Install the Rear Drive Gear Bearing (31) and Front Drive LENGTH OF BEARING
Gear Bearing (30) onto the Drive Gear (29). Needle Bearing Inserting Tool
2. Install the two Drive Gear Keys (37) into the drive gear shaft, (Dwg. TPD786)
10. Install the Drive Housing O-ring (35) onto the Drive
Housing.
11. Install the Drive Housing onto the Gear Case, aligning the
punches.
12. Install the eight Drive Housing Cap Screws (40) and Drive
Housing Cap Screw Lock Washers (41). Tighten to 28 ft-lb
(38 N'm) torque.

~41 /
~40

(Dwg. TPD1171)
3. Slide the Rear Drive Gear Bearing into the Gear Case.
4. Lubricate the Drive Gear with approximately 8 oz (240 ml)
of Ingersoll-Rand No. 28 Lubricant. 32
5. Press the Drive Gear Shaft Seal (34) down into the Gear
Case Cover (32) lip facing upward.
6. Install L1eGear Case Cover O-ring (33) onto the Gear Case
Cover.
7. Install the Gear Case Cover into the Gear Case. (Dwg. TPD1168)

18
 · " Pre-Engaged Drive 9. Assemble the Drive Gear Screw (34), Drive Gear Lock
For Models ST7SOGBDP03R31, ST750GBDP03L32, Washer (35), Drive Gear Cup (36) and Drive Gear Screw
'" ST750GCDP03R25, ST750GCDP03L26, O-ring (37).
STI50GCDP03R51, ST750GCDP03L52, 10. Grasp the Drive Shaft (57) in a vise, external splined end
~ ST799GBDP03R31, ST79SGBDP03L32, down. Place assembled Drive Shaft Screw Unit into the Drive
ST799GCDP03R25, ST799GCDP03L26, Shaft, screwhead down. Lubricate the inside diameter of the
ST799GDDP09R51 and ST799GDDP09L52: Drive Shaft with Ingersoll-Rand No. 28 Lubricant.
(Refer to illustration on page 30). I 11. Slide the Drive Gear Bearing (30) into the Drive Shaft.
12. Lubricate with Ingersoll-Rand No. 28 Lubricant and in-
Gear Case
stall the Driving Clutch Jaw teeth facing up and Driven Clutch
1. Place the Drive Gear Bearing Retainer over u1e rear end of
Jaw teeth facing down into the Drive Shaft
the Drive Gear. I
13. Insert the Clutch Spring (51) into the Drive Shaft
2. Using an arbor press, press the Rear Drive Gear Bearing (31)
14. Insert the Clutch Spring Cup (50) into the Drive Shaft
onto the rear end of the Drive Gear.
15. Press the inserted parts into the Drive Shaft, and install the
3. Using a plastic hammer, seat the Rear Drive Gear Bearing
Clutch Spring Cup Retainer (49).
into the Gear Case by tapping the opposite end of the Drive
Gear.
4. Using retaining ring pliers, install the Drive Gear Shaft
Bearing Retainer (33). ' 16. If it is necessary to replace the Drive Housing (40) and
drive components, make sure that the Piston Seal (part number
5. Using retaining ring pliers and working through the access
holes in the gear web, instal! the Drive Gear Bearing Retainer. 5S800-272) has been removed from the rear of the new Piston
(54). The Piston Seal must be removed to prevent pressure
build-up which will cause movemenrofthe Planet Gear Frame
Shaft Seal (16). If this condition occurs, the Piston cannot re-
tract and the Drive Pinion (63) will remain in engagement with
the flywheel, causing damage to the Starter drive train and/or
Starter motor. To remove the Piston Seal, insert a screwdriver
32 inside the lip of the Seal and pry it loose from the Piston.
17. Install the Piston (54) onto the Drive Shaft until the Rear
Drive Shaft Bearing seats into the Piston.
18. Using a thin flat blade screwdriver to assist in this opera-
tion, coil the Large Drive Shaft Bearing Retainer (53) into the
groove.of the Piston to retain the outer race of the Drive Shaft
28 Bearing.
19. Using O-ring lubricant. lubricate the Piston O-ring (55)
and install it in the groove of the Piston.
20. Position the Drive Housing in an arbor press, pinion--end
down and install the Drive Housing Seal (43) into the Drive
Housing. Using a pressing sleeve of the proper size, press the
Seal into the Drive Housing so that the lipofthe seal faces away
from the Drive Pinion.
21. Using a sleeve that contacts the outer race of the Front
Drive Shaft Bearing (4), press the Bearing into the Drive Hous-.
ing until it seats, For "B" and "C" ratio models only, drop the
(Dwg. TPD1170) Piston Return Spring Seat (60) on top of the Front Drive
6. Lubricate the Drive Gear with approximately 8 oz. (240 rnl) Shaft Bearing. (See illustration on page 30.)
of Ingersoll-Rand No. 28 Lubricant. 22. Slide the Piston Return Spring (59) onto the Drive Shaft
7. Press the Rear Dri ve Shaft Bearing (58) onto the Drive Shaft and snap it into the front of the Piston so that it is against the
8. Slide the small bearing retainer convex side first, onto the Large Drive Shaft Bearing Retainer (53).
Drive Shaft Press it into position in accordance with the 23. Lubricate and insert the assembled Drive Shaft into the
instructions packaged with the new Retainer. Drive Housing.

19

~tffl_?l!C'-=
 '" 1-:-

24. Using O-ring lubricant. lubricate and install the Outer

,
Intermediate Gear Case, Motor Housing, Motor
~ Bulkhead O-ring (47) and the Inner Bulkhead O-ring (48) on Assembly and Housing Exhaust Cover
the Bulkhead (45). 1. Using a bearing pressing tool of the proper size, press the
25. Slide the Bulkhead onto the Piston. Front Gear Frame Bearing (17) into the rear of the Intermediate
26. With the Drive Housing in the ar~r press. press down on Gear Case (13). Place Spacer Ring (l6A) on Bearing.
the rear face of the Piston. I 2. Using a sleeve which contacts the outer ring of the seal,
!I press the Planet Gear Frame Shaft Seal (16) into the rear of the
Intermediate Gear Case over the Front Gear Frame Bearing.

Feel the underside of the Drive Hou~ing to make sure the

I
Drive Shaft passes through the Bearing.
Make sure the flat side of the Seal is installed against the
27. Using a screwdriver, instal! the Bulkhead Retainer (45).
Bearing.

~
Make sure the Bulkhead Retainer
, is properly seated in the
Motor Housing groove before easing off the arbor press.
Failure to do so will allow improperly retained parts to sep-
arate when removed from the arbor press resulting in
injury to personnel
28. Remove the Drive Housing from the arbor press.
29. Using O-ring lubricant, lubricate and install the Drive
Housing O-ring (41) in the groove of the Drive Housing.
16
30. Position the assembled Gear Case on a workbench. The
assembled unit must be upright to accept the Drive Housing.
31. Carefully position the assembled Drive Housing (40)onto
l:~
the Gear Case so as not to damage the Piston Seal. Align the
punch marks of the Gear Case and Drive Housing. (Dwg. TPD1172-1)
32. Install the Drive Housing Cap Screw Lock Washers (39)
and the Drive Housing Cap Screws (38) and tighten to 28ft-Ib
3. Install the Rear Gear Case O-ring (14) in the groove at the
rear of the Intermediate Gear Case and the Front Gear Case
4
(38 Nm) torque. O-ring (15) in the groove at the front of the Intermediate Gear
33. Using an impact wrench with a 5/16" (8 mm) x 8" Case. Coat both O-rings with O-ring lubricant .
(203 mm) long hex inserted into the end of Drive Shaft, tighten 4. Install one Gear Shaft Retaining Washer (23) on the front
the Drive Gear Screw (34) to 57 ft-Ib (77.3 Nm) torque. Ofthe Planet Gear Frame (18). Press the From Bearing Spacer
34. Lubricate using Ingersoll-Rand No. 11 Grease and (25) on the front shaft of the Planet Gear Frame to hold the Gear
slidethe Pinion Spring (65) and the Pinion Spring Sleeve (64) Shaft Retaining Washer snugly in position.
over the Pinion end of the Drive Shaft
•
i~.J Nt

35. Lubricate the Pinion end of the Drive Shaft with

Ingersoll-Rand No. 11 Grease and install the Drive Pinion
(63). I stalling it. Be careful not to gouge or scratch the Front
36. Grasp the Drive Pinion i: zcopper-covered vise with the
Starter supported on a workbench.
37. Place the Drive Pinion Washer (62) onto Drive Pinion
Retaining Screw (61).
Models ending in R25, R31 and RSl have a left-hand
thread; models ending in L26, W2 and L52 have a right-
hand thread. Install the Drive P'•Ilion
. Retaining Screw into the
end of the Drive Shaft and tighten it to 80 n-tb (108.5 Nm)
torque for models with "B" and "C" gear ratios and to 125
ft-Ib (169,5 Nm) torque for rnod-' "t.h "D" gear ratio.
Coat the Front Bearing Spacer with Gear Lube before in-
Bearing Spacer during installation as this could result in·
leakage between the Planet Gear Frame 'and Gear Case.
5. Place Planet Gear Frame on a bench, shaft side down. Place
the Planet Gear Bearing (20) inside of Planet Gear (19). Place
Bearing Spacers (21) on top and bottom of Bearing and Gear.
Slide the components into the slots in the side of the Planet
Gear Frame. Align holes in Spacers and Bearing with holes in
Planet Gear Frame and insert Planet Gear Shaft (22), integral
keyed end down, through the Spacers and Bearing so that the .
larger portion of the keyed end of the Shaft contacts the Planet
Gear Shaft Retaining Washer. Repeat the procedure for the two
remaining Planet Gears and Components.

4
20 1
 ·
,
10. Clean the threads of the Intermediate Pinion Retaining
., Screw (27) and apply 2-3 drops of Penna bond HMl18** to the
Do not move or turn over the Planet Gear Frame until threads approximately 3 mm from the end of the Screw. Install
steps 6 and 7 have been completed. Movement of the Screw and tighten enough to hold assembly together.
( Planet Gear Frame Assembly could dislodge assembled 11. For final lightening, position the Intermediate Gear Case so
components, making it necessary to repeat Step 5. the Intermediate Pinion is secured in the jaws of a copper-
6. Install the other Planet Gear Shaft Retaining Washer over faced vise. Tighten the Intermediate Pinion Retaining Screw to
the shaft at the rear of the Planet Gear. I . 90 ft-lb (122 Nm) torque.
7. Using the proper size bearing inserting tool, press the Rear
Gear Frame Bearing (24) on the shaft at the rear of the Planet
Gear Frame.
21

24

25

(Dwg. TPD1167)
8. Slide the Planet Gear Frame Assembly, coupling end first,
into the rear of the Intermediate Gear Case (13), making sure
that the Planet Gears mesh with the ring gear. Use care so as to
not damage the seal.
15
(Dwg. TPD1204)
12. Remove the Intermediate Gear Case from the vise and set it
on a bench.
The. Intermediate Gear Case will work in only one
orientation.
Align the punch marks on the Interm ediate G ear Case and Gear
Case and using a plastic hammer, tap the Intermediate Gear
Case until it seats in the rear of the Gear Case. Make sure the
Intermediate Pinion meshes with Drive Gear.

13

(Dwg. TPD~173)
9. Install the Intermediate Pinion (26) making sure that the
notches at the rear of the Pinion align with the notches and
tangs in the shaft of the Planet Gear Frame.

(Dwg. TPD1165)
**Registered trademark of Penna bond Corp.
~
13. Before installing the Motor Assembly, coat the O-rings on 15. Install the Splash Deflector (3), Deflector RetaiL:. o

the Motor Assembly and the inside of the Cylinder with O-ring Spring (4) and gef':.:: •. or Retaining Screw (5) in the re+ G: tile
li.cricant, Install the MO:.Jr Assembly through L..'1~ rear of the Housing Exhaust Cover.
Motor Housing with the geared e~d of the rotor toward the
front.

Turn the Intermediate Pinion so that the gear on the rotor Coat the threads of the Deflector Retaining Screw with
Ingersoll-Rand 5MB-441 Sealant.
meshes with the Planet Gears. Make sure that the rear of
the Motor Assembly is installed flush with the rear of the
Cylinder,

12,\

(Dwg. TPD1161)
14. Align the punch marks on the Motor Housing with the
punch l1arks on the Intermediate Gear Case and using aplastic
hammer, tap the Motor Housing until it seats on the rear of the
Interrnedia te Gear Case.
8
(Dwg. TPD1160)
16. Coat the Exhaust Cover Seal (2) with O-ring lubricant and
install in the groove on the Housing Exhaust Cover.
17. Align the punch marks on the Housing Exhaust Cover with
the punch marks on the Motor Housing and using a plastic
hammer, tap the Housing Exhaust Cover until it seats.

(Dwg. TPD1163)

22

/
 , {
13.1nsw.:: _,e Housing Exhaust Cover on the rear of we Motor
Hou$:.~Z "sing the Starter Assembly Cap Screws (6) and Cap
Sc::e'v ','/::.shers (70). Use an g mri hex-head wrench to tighten
each a little at a time to a final torque of 45 to 50 ft-lb (61 to 68 Use Ingersoll-Rand 5MB-4-H Pipe Sealant on all plugs.
J,
\ Nm) increments. 19. Install the bottom Housing Plug (10) and the Housing
7
6
Plug Inlet Boss (11). Put the Starter on its side with the side
plug hole upward. Add 175 rnl (approximately 1/3 pint) of
Dexron® ** II Automatic Transmission Fluid through the
side plug hole.

Do not overfill.
Install the side Housing Plug (10) and tighten all plugs to 5 to
10 ft-Ib (6.8 to 13.6 Nm) torque.

(Dwg. TPD1183)

( ( ...

.. ~.

**R~ ..>"steredtrademark of En on Corp.

(t
V)

23

;.~~~. row__ 4 _
 ,.
.. I TEST AND INSPECTION PROCEDURE
I \
1. Clutch Ratcheting: Turn the Drive Shaft Pinion (63) by
tt
hand in the direction of Starter rotation. The clutch should
ratchet smoothly with a slight clicking action.
2. Motor and Gearing Freeness: turn the Drive Shaft Pinion
(63) opposite the direction of Starter rotation. The Drive Shaft
Pinion should turn by hand.
Inadvertent application of air ::;ressure to the "OUT" port
will result in Drive maifunction (pinion will fail.to retract).
If this condition occurs, loosen Drive Housing Cap Screws
(38) to vent Gear Case (21). Also, loosen Housing Plugs (10)
and (11) to vent Motor.
3. Pinion Engagement: Apply 50 psig (3.4 bar(345 lcPa)
pressure to the engagement "IN" Port. Drive Shaft Pinion (63)
should move outward and air or gas should escape from the
"Out" Port Plug the "Out" Port and apply 150 psig (10.3
bar/l034 kPa) pressure to the "IN" Port. Check and make sure
no air or gas is escaping. Measure the dimension from the face
of the Drive Shaft Pinion (63) to the face of the mounting
flange. It should be 2-23/32" (69.0 + 2.0 mm) for models with
"B" and t'C" ratio gearing and 8-3/4" (222 + 2.0 mm) for
models with "D" ratio gearing. Remove the pressure from the
"IN" Port. Measure the distance from the face of the Drive
Shaft Pinion to the face of the mounting flange. It should be
1-25/32" (45.0 + 2.0 mm) for models with "B" and "C" ratio
gearing and 7-3/32" (180+ 2.0 mm) for models with "D'tratio
gearing.
4. Motor Action: Secure Starter in a vise and apply 90 psig
(6.2 bar/620 lcPa) pressure using a 3/8" (9 mm) supply line to
,
I
the inlet of the motor. S tarter should run smoothly.
5. Motor Seals: Plug the exl.aust and slowly apply 20 psig
(138 bar/138 lcPa) pressure to the inletof the motor. Immerse
the Starter for 30 seconds in a nonflammable, bubble-produc-
ing liquid. If the Starter is properly sealed, no bubbles will
appear.
6. Gear Case Seals: Plug the exhaust and slowly apply 20 psig
(1.::'8 bar/138 lcPa) pressure to the inlet of the motor. Immerse
the Starter for 30 seconds in a nonflammable, bubble-produc-
ing liquid. There should be no leakage in the housing joints in
the Gear Case area or in the shaft seal in the Intermediate
Gear System. If the S tarter is properl y sealed, no bubbles will
appear.
7. Confirm Motor Rotation: Remove Housing Plug (10).
Use a 1/4" hex drive to rotate the motor to verify proper motor
adjustment, Intermediate Gearing output should rotate oppo-
site the required S tarter rotation while observing from the pin-
ion side. Replace Housing Plug.
24
8. Orientation: Drive Housing must be assembled to cus-
tomer orientation or per engineering drawing. If orientation is
not specified by customer, standard orientation will be
supplied. Check dimension prints on pages 4,5, and 6.
9. Confirm Drive Rotation: Apply low pressure to motor and
observe rotation. Drive Pinion (63) must rotate in the direction
stamped on the nameplate. Chamfer on pinion teeth should be
on trailing edge of gear tooth.
10. Bendix Drive Function-Inertia Models Only: Install
Starter on testing fixture, Apply low pressure air to motor.
Bendix must engage according to specified rotation.
11. Drive Housing Function-Pre-Engaged Models Only:
Apply 150 psig (10.34 bar/l034 kPa) to "IN" port of Drive
Housing (40). Cycle five times. Air should exhaust through
"OUT" port during each cycle.
12. Free Speed (All Models): Install the Starter on a testing
fixture with proper containment system. Apply 90 psig (6.2
bar/620 kPa) to motor inlet. Free speed specifications should
be as follows:
MAXIMUM MINIMUM
UB" ratio 4800 rpm 4500 rpm
ue· ratio 4130 rpm 3880 rpm
UO" ratio 3100 rpm 2870 rpm
13. Exhaust Deflector Operation: Install Starter on testing
fixture. Apply low air pressure to motor and observe. Deflector
must return to its normal position after operation of the Starter.
14. Concentricity and Squareness of Shaft to Housing "D"
Ratio Only: Assemble indicator on shaft, Indicate pilot
diameter. Check squareness of face at mounting surface. Pilot
diameter must be concentric within .008 rnax. T.I.R. Mounting
face must be square with shaft within .W4 TJ.R. max,
15. Drive Housing Leakage-Pre-Engaged Models Only:
Plug Drive Housing (40) "our port and apply 150 psig
(10.34 bar/l034 lcPa) to "IN' port to extend Drive Shaft (57).
There should be no leakage. .
16. Test Pinion Engagement-Pre-Engaged Models Only:
Plug "OUT' port in Drive Housing (40). Apply 70 psig (4.83
bar/483 lcPa) as needed. In its normal position, the distance
from the mounting flange to the end of the Drive Shaft (57)
should be 1-3/4". In its extended position, the distance from
the mounting flange to the end of the Drive Shaft should be
2-7/8". While the Drive Shaft is extended, push Drive Pinion
(63) back on helical splined :rart. Rear face of Drive Pinion
must move back .47" ± .035 .
17. Drive Shaft Seal Leakage-Pre-Engaged Models Only:
Plug ':OUT' port on Drive Housing (40). Apply 90 psig (6.2
bar/620kPa) to "IN' port and 20psig (138 bar/138kPa) to the
vent hole. After five seconds, there should be no leakage.
 .~ .,
TROUBLESHOOTING GUIDE
"
Trouble
I ~o
Probable Cause
c
, Solution

(f air supply. Check for blockage or damage to air supply lines or

Damaged Motor Assembly (12).
\
Foreign material in Motor
I '
Motor will not run and/or piping.
Blocked exhaust system.
Defective Control or Relay Valve.
Low air pressure to Starter.
Restricted air supply line.
Relay Valve malfunctioning.
Loss of power Exhaust flow restricted.
Darnag cd Motor Assembly.
tank.
Inspect Motor Assembly and power train and repair -
power train or replace MOLOrAssembly if neces
saary.
Remove Motor Assembly and piping and remove
the blockage.
Remove Housing Exhaust Cover (1) and check for
blockage.
Replace Control Valve or Relay Valve.
Check air supply.
Check for blockage or damage to air lines.
Clean or replace lines or Relay Valve. Lubricate
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.
Replace Motor Assembly.

(m; For Models with Inertia Drive:

i Foreign material in Starter Drive. Remove obstruction.
I Damaged or worn Drive parts. Check Drive components and replace if necessary .

.•. ' ,

70r Models with Pre-Engaged Drive:

Drive (36) or (57)
will not engage.
Motor runs, Pinion engages,
but does not rotate flywheel.
Excessive butt
engagement,
I No pressure to Drive Housing Check air supply. .
,
port.
Internal Drive Housing ports Remove blockage.
blocked.
Fluid in drive unit components. Remove fluid.
I
Damaged or worn Piston Replace damaged or worn parts.
Assembly (54), O-rings or seals.
O-rings and seals dry. Relubricate O-rings and seals.
Damaged or broken drive train. Disassemble drive train and replace worn or
damaged parts.
Damaged Drive Pinion (36) or Inspect Drive Pinion and flywheel and replace if
(63) or flywheel. necessary.
Damaged Stsrter Drive (36) or Inspect Drive components and replace worn or
(57) components. damaged parts.
Low air pressure. Check air supply.
Wrong Drive Pinion. Replace with proper Drive Pinion

25 -,

-,
.,.- .'
 _ ~_.-'..J,-,.;-:,JOTINGGUIDE (Continued)
-- -- •. --,~.-
Trouble j Probable Cause
Oil in air supply line.
Oil blowing out of Splash Deflector Retaining
exhaust Screw (5) or pipe plug missing.
Worn or damaged rotor seals or
(
static O-rings.
Worn or damaged O-rings.
Loose joints.
Oil leaking from Excessive high-speed operation.
Gear Case (28). High number of start cycles.
Loose or leaking Pipe Plugs
(10) or (11).
Splash Deflector Retaining Screw
or Pipe Plug missing.
Loose joints.
Air or gas leakage. Excessive high-speed operation.
,
High number of start cycles.
Loose or leaking Pipe Plugs.
Splash Deflector Retaining Screw
loose or pipe plug missing.
26
Solution
Inspect air line and remove source of oil.
Install Splash Deflector Retaining Screw or Pipe
Plug.
Replace static seals on outside of Motor or send
MOlar to Ingersoll-Rand to be rebuilt.
Replace O-rings.
Make sure that joints fit properly and Starter
Assembly Cap Screws are tightened to 60 ft-Ib
(81 Nm) torque. Make sure all seals and O-rings fit
and seal properly at their perimeters. If they do not
replace with new seals and O-rings.
Operate according to recommendations.
Replace worn components.
Tighten or replace Pipe plugs using Ingersoll-Rand
No. 5MB-441 Pipe Sealant
Tighten Splash Deflector Retaining Screw or
replace Pipe Plug.
Make sure that joints fit properly and Starter
Assembly Cap Screws are tightened to 60 ft-Ib
(81 Nm) torque. Make sure all seals and O-rings fit
and seal properly at their perimeters. If they do not
replace with new seals and O-rings.
Operate according to recommendations.
Replace worn components.
Tighten or replace Pipe Plugs.
.
Tighten Splash Deflector Retaining Screw or
replace Pipe Plug
 \ ;,-~
t•
. =:;..

.~
.~ . ,-.....,

Series STIOO Turbine Starters

ST12S' C; ~ L c. 34 41 40 38

S t>~-\-,

11

5T750GBOI03R31
5T750GBO I031_32
5T799GBOI03R31
5T799GBOI03L32
35

.5
tv
-.-J

.38
39
47
5T750GBOP03R31
,45 5T750GBOP03L32
, 51 5T750GCOP03R25
17 \ 27 5T750GCOP03L26
26 5T799GBOP03R31
5T799GBOP03L32
6 7 8 24 10 5T799GCOP03R25
5T799GCOP03L26

65
ST750GOOP09R51
5T750GOOP09L52
ST799GOOP09R51
ST799GDDP09L52
40
4\

(Dwg. TPA1275-2)

,.
 Solar-Turbines RETROFIT KIT DRAWING
A ClltlJrpillar eomp.,y

INGERSOL RAND STARTER CHANGE

VANE TYPE TO TURBINE TYPE
PRODUCT: CENTAUR

MODEL: Hand TARUS CS/MD

CUSTOMER: GENt:RIC

PURPOSE
To provide documentation to retrofit the pneumatic IRvane type starter motors to the pneu-
matic IR turbine type motors.

SCOPE
There are two fundamental configurations of starter inlet plumbing systems on the s'arter
motors and combining gearboxes. This kit address only those start systems that do not
already have a 'Y' inlet gas manifold incorporated in the starter inlet plumbing. And, have
only a single metal flex starter inlet hose.
This retrofit will require only the change ofthe starter motors, and, inlet and exhaust plumb-
ing modifications. The combining gearbox will not be changed.
Due to the many different types of piping configurations, that supplies the gas to the start-
ers, and the different exhaust piping configurations, pipe cutting and welding WILL be re-
quired. Drilling and tapping may also be required for frame mounted brackets.
REFERENCE
This kit drawing is associated with kit number 179863K 100

a v v--- /-1 ,",;/ e. L-- "5 14()D

Sf 100~)ol
r.e«

PROJECT DATE DCL RELEASE DRAWlNGNO.

Ed Stewart 6-7-93
DESIGN
6-7-93 2 @ 176458-0
D.L. Williams
CHECK REV. SHEET
Ed Hart 6-7-93 CODE
DRAFT IDENT. 66195 N/C 1 OF 28
D.L. Williams 6-7-93
These specifications were developed with no representation in regard to proprietary rights in the design and without considering whether
patents mayor may not be involved. In all cases. therefore. the supplier shall be required to assume liability with respect to patents of others.
Solar-Turbines RETROFIT KIT DRAWING
A c• ."".,. Company

TABLE OF CONTENTS

Instalation Parts List 3

Pre installation Briefing (special tools) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
Hydromechanical Schematic 13
System Functional Description 16
Component Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18
Operations Maintenance . . . . . . . . . . . . . . . . .. 20
Calibration & Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23
Site Manual updates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Service Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25
Supplemental Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26
Revisions 28

SAFETY NOTES

• A total regard and commitment to safety requirements is emphasized when carry-

ing out any work to remove or install any equipment discussed in this kit. General
·Safety Requirements" are discused in the Operation and Maintenance Instruc-
tions manual. It is also a requirement that the following safety procedures be tol-
o lowed to ensure safety to personnel and equipment.

• Ensure battery charger, control console, and switchgear circuit breakers are
opened. Tag master switch, start buttons and controls with "DO NOT OPERATEn
tags prior to beginning work.

• Check atmosphere using a gas detection device (sniffer) for explosive gases be-
fore opening explosion proof boxes.

• Before dismantling any liquid lines or pneumatic lines, ensure that all pressure has
completely dissipated and all shutoff valves have been closed and a tag "DO NOT
OPEN- placed visibly on them. Buffer gas lines may carry in excess of 1500 PSI.
Hydraulic start lines may carry in eXCt;lSSof 5000 PSI.

• Stand clear of all pressure lines and fittings during start.

• Check all piping for structural soundness. Verify that piping is properly supported
and all connections are made in accordance with standard practices. Avoid ':.JURY
RIGGING- or make shift plumbing at all times.

• This document is intended to be used as a supplement to the customers Opera-

tion and Maintenance Instructions manual after retrofit kit installation.

DRAWING nTLE DRAWING NUMBER REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type
176458-0 N/C SHEET 2 OF 28
--
•

Solar-Turbines RETROFIT KIT DRAWING

A C.lfpi"" CompllllY

1 INSTALATION PARTSLIST

1.1 REFERENCE

PART NO. DESCRIPTION aTY.

176458-0 Kit Drawing 1 ea

1.2 INLET PLUMBING

PART NO. DESCRIPTION aTY.

965213C1 Gasket (spool piece) 2ea
- For this application, the existing pulmbing will be resued with the exception of the
lubricator. A spool piece will be required to replace the lubricator. This spool piece
will be customized, on site, for a field fitup and therefore has no part number.

1.3 STARTER MOTORS

PART NO. DESCRIPTION aTY.

~ 190475-1 Start motor, Turbine style 2ea
190475-3 Exhaust elbow 2ea

1.4 EXHAUST PLUMBING

-
PART NO. DESCRIPTION aTY.
903732C1 O-ring (split flange existing inlet) 4ea
230098-100 ~dpter, exhaust 4 bolt to round 2 ea
230275-1 Gasket (starter exhaust) 2ea
903735C1 Clamp, split flange 3" 2ea
23641R1 Bolt, 5/8-11 uncx1.75 8ea
903249C1 O-ring (split flage, exhaust) 2 ea
953993C1 Buttweld o-ring end flange 2ea

DRAWING TITLE DRAWING NUMBER Rev.

Ingerso! Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET 3 OF 28
, -
. Solar-Turbines RETROFIT KIT DRAWING
A Clllerpi/llJ( ComPIJffY

2 PRE INSTALLATION BRIEFING

• Review Fig #5, 'Relitive Dimensions', To Evaulate Possible Interference Problems.

• It Is Recommended, That The Installer Confirm That The Kit Supplied Will Suport
The Level Of Parts Required To Reassemble The System. The Dii~erentVariations
Of This Kit Can Be Identified By The 'dash' Numbers.

• Dash 100, addresses only those systems that do not have a 'Y' manifold but do
have a single metal flex hose in the inlet plumbing.

• Dash 200, addresses only those systems that do have a 'Y' manifold and have two
metal flex hoses in the inlet plumbing.

• Proper Identification Of The Starter Speed Requires Reference To The Start-

er Pinion gear. Speed Will Have Inpact On The Retrofit. The speed of the sys-
tem will not be changed as a part of this retrofit.

• The reduced speed start systems, have a starter pinion with 23 teeth and an
approximate diameter of 3 1/16 inches.

• The nonreduced speed start systems, have a starter pinion with 21 teeth and an
approximate diameter of 2 7/8 inches.

• Maximum Starter Gas Supply Pressure 225 Psig. Range is 165 to 225 psig.

• High Quality Metric Allen Wrenches Will Be Required Including 8 & 10 Mm.

• If Any Pipe, That Is Not Supplied In This Kit Is Used In The Retrofit, It Must Be Of
The Same Schedual, Quality And Material As That Which Is In The Circuit.

• A Torque Wrench With A Range Including 50 And 90 Foot Pounds (122 And 67.8
Newton Meters) Will Be Required.

DRAWING TITlE I DRAWING NUMBE~ REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type
I 176458- 0
N/C SHEET 4 OF 28
, ---------
Solar Turbines RETROFIT KIT DRAWING =>l
A Catcrp;!'dr Comp8flY

3 INSTALLATION INSTRUCTIONS

3.1 REMOVING THE OLD SYSTEM

This Illistration Should Be The Starting Point For Systems Not Built On The Universial
Generator Skid.

t.
Figure 1. VANE STARTER MOTOR SYSTEM INLET WITH LuBRICATOR

1. Isolate the oil supply to the lubricator and plug the line.
2. Measure and record the flange to flange length of the lubricator spool if you need
to prefab the spool away from the site.
3. Measure and record the distance from the face side of the combing gearbox to the
center line of the existing start motor's inlet port.
4. Measure and record the distance from the face side of the combing gearbox to the
center line of the existing exhaust port.
5. Disconnect and remove the inlet plumbing between the inlet side of the lubricator
and the starter motors.
6. Retain, and keep clean, the inlet plumbing between the outlet side of the lubricator
and the starter motors. You will be reinstalling it.

DRAWING TITLE ~RPWING NUMBER REV.

Ingersol Rand Sta~er Change 176458-0
Vane Type to Turbine Type N/C SHEET 5 OF 28
SolarIurbines RETROFIT KIT DRAWING
A ClJlclpi1lar COInfWIY

7. Disconnect the exhaust plumbing from the starter motors.

8. Remove the exhaust plumbing to the extent that there is clearance to pull the old
motors and reinstall the new ones.

Fig,ure 2. VANE STARTER MOTOR EXHAUST MANIFOLD

• Figure 2, is a package that has not yet been modified. It is intended that the com-
bining manifold be reused. It should be modified at a point on each branch to make
the transition to the Buttweld end flange at the starter; even if the customer's other
piping must be modified to fitup.

DRAWING TITLE DRAWING NUMBER REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET .3 CF 28
.__ ... --~- .- - -- - .__ . ---- - --- .... _-
Solar'Turbines RETROFIT KIT DRAWING
A Caterplilill Cor-;an,

/" ,qif.i;
-~A, ""
~ •• ,If.IT,I
.
8f)----G~·\"'e'~!j ~--J€i-!.
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rs
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. <----------- . -- '''" ,!
;
'
! 12 214

,,-'-
,
20

/ .A
.----..---._---...----..1
23

Figure 3. VANE TYPE STARTER MOTOR ASSEMBLY

9. Unscrew the motor housing cover cap screws #4

10. If You Do Not Have The Reduced Speed Configuration, Remove The Vane
Type Motors Only.

11. ONLY; IF YOU HAVE THE REDUCED STARTER SPEED CONFIGU-

RATION, WILL YOU NEED TO REMOVE AND INTERCHANGE THE
PINION GEARS #20 & #25. Refer to preinstallation breifing for sizes.

12. If Necessary to remove the pinions, clamp the pinion in a soft jawed vice or hold
with a strap wrench and unscrew the Allen head screw #19. This is a metric 10mm
bolt.

13. If Necessary, Install The Pinion Gears From The Vane Type Starters Onto The Tur-
bine Type Motors And Torque To 90 Foot Pounds Or l22 Newton Meters. No Seal-
ant Is Required On This Bolt.

14. Clean and inspect all sealing surfaces and o-ring groves.

DRAWING TITLE I DRAWING NUMBER REV.

Ingersol Rand Sta!ter Change 176458-0

Vane Type to Turbine Type N/C I SHEET 7 OF 28
------ -- ---------------- --------------------
--,
Solar-Turbines RETROFIT KIT DRAWING
A Caterpillar Company

3.2 INSTALLING THE NEW START MOTORS

• If You've Had The Gear Case Off, For Any Reason, Do Not Try To Install The Motors
And The Gear Case As An Assembly. The Gear Case Must Be Separated From The
Motors.

• The Starter Motors Must be lubricated. They require 5.33 ounces cr 158 cm3 of
Dextron 2 Automatic Transmission fluid. Turbine lube oil is an acceptable substi-
tute.

1. If removed, install the motor gear case onto the accessory drive gearbox ensuring
that the output coupling is engaged.

2. Replace o-rings on the motor assembly if damaged.

3. Install the new turbine type motors. The inlet and exhaust ports oreintated as shown
in figure #4 may be rotated by any 900 increment of the bolt pattern.

4. Torque the motor case bolts to 55 foot pounds or 75 Newton meters.

\ ..;:.,/ e \ '\ '.\ \'\','\

STARTER \ \ ,yo '-.". •• ',.' ~). ~Ii\ ...
. . ' , v' I '
\ --!1...,.[ 1'\\I \i "4/",I \ \
Start Motors
U922
GEARBOX--- ,--\-

• ~
..
,/1
~'"
\j"

0
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' »:
»:'

1
:1
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,/ "., '\J; ,......."'.... .1, ",." \ •.•..
_
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/ ",' , .,,1

Case 't~~tlts
//'"
~'
-.
/
/
5S#lOy'
~--,-:==-::=-,:;::;~~. --
'~/
Q. ' •••. , ""- --,.-/

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'<C''''

9•
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<,~ '. ....
.......... ~.
..,
/..;),;:;- .
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.. ""'I\.."~//':: c{)
,/

'"

Figure 4. Turbine Starter Motors

PART NO. DESCRIPTION QTY. INDEX
190475-1 Starter 2 ea M922
190475-3 ExhaustElbow 2 ea Ref

1
DRAWING TITLE
Ingersol Rand Starter Change
Vane Type to Turbine ______
Type ~
I DRAWING NUMBER
176458 - 0
REV,

N/C I SHEET 8 OF 28
-LJ __ ~~ ~---
SolarIurbines RETROFIT KIT DRAWING
A Cl1lerpiflat Company

3.3 INSTALLING THE INLET PLUMBING

~l~~I~
Figure 5. Retrofitted Inlet System With Spool Installed

5. Reassemble the old plumbing beginning at the starter. When you get to the point
where the lubricator was, plumb and square the piping, measure the open in the
circuit, and fabricate a spool piece to fit. It is reccomended that a welded detail be
n
used. However, if a 5.25 or 13.3 cm threaded schedual80 pipe coupling is avail-
able, it COL!ldbe used in place of the lubricator.

6. Install the spool piece and gaskets and button up the details. Be sure not to create
any stress in the plumbing that will be transmitted to the starters.

PART NO. DESCRIPTION QTY.

965213C1 Gasket (spool piece) 2ea

ORA,,"NG nTlE ~",WING NUMBER REV.

Ingersol Rand Sta!ter Change 176458-0
Vane Type to Turbine Type N/C SHEET 9 OF 28
SolarIurbmes RETROFIT KIT DRAWING
A CtIIlerp,IIN COfIItUIIY -
3.4 INSTALLING THE EXHAUST PLUMBING

:~
Adapter, exhaust round to 4 boltl I

Clamp, Split flange 14

Bolts S/8-11X1.7515

O-Ri~r
e 8 ,>
,~
.)("/ ....

~/ .:.;:'

. Figure 6. NEW TURBIKIE TYPE MOTORS CUSTOM EXHAUST

• ATTHIS POINT, THE INSTALLER WILL NEED TO CUSTOMIZE THE CONNEC·

TIONS TO THE EXISTING EXHAUST MANIFOLD.

1. If not already fitted, install the exhaust adaptor and gasket on to the starter exhaust
elbow. The IR factory often installs a weldment on the down stream side of the ex-
haust elbow. It looks like a stainless steel spacer. has an o-ring grove and is drilled
with the bolt pattern of the exhaust elbow It will not be used in this application and
can be removed.

2. Bolt on the #13 pipe fitting, plan on how to run out the exhaust and weld up a trans-
sion to the customer's existing piping.

3. A bracket. to support the exhaust manifold, will be required. It will need to be cus-
tom made, on site, to fit the package due to unique piping configurations. Be sure
no stresses or torques are transmitted to the start motors or the exhaust elbows.

PART NO. DESCRIPTION orv INDEX

230098-100 Adptor, exhaust round to 4 bolt 2 ea 11
230275-1 Gasket (starter exhaust) 2 ea 12

DRAWING TITLE, DRAWING NUMBER REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type
176458-0 N/C SHEET 10 0= 28
--------_._- . -- ----
-
 Solar-Turbines RETROFIT KIT DRAWING
__________________________________________________________________________________________ '---.aG
A CiJte'~i/lar C~If>Nny

PART NO. DESCRIPTION aTY. INDEX

953993C1 Buttweld 0- ring end flange 2ea 13
903735C1 Clamp, split flange 3" 2 ea 14
23641R1 Bolt,5/8-11UNCX1.75 8 ea 15
903249C1 0- Ring (split flange, exhaust) 2 ea 16

Figure 7. A COMPLETED INSTALLATION

• Figure 6, shows the Turbine type motors installec.. This customer had a different
type of combining manifold that fit best on the inboard side of the duplex filters.
Please note that the customer has another suport ( a turnbuckle & cable) to carry
the load of their exhaust piping. The small support shown, only supports the
wieght of the combining manifold.

DRAWING TITLE DRAWING NUMBER REV,

Ingersol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET 11 OF 28
,------
. Solar-Turbines RETROFIT KIT DRAWING
A (;«'11';" ~

4 ILLUSTRATIONS

L
r---
I
424mm.~

existing. I
l.-226-+!
mm
exhaust!

j~ust Hi
rr--,....I
ENGINE
I I l

l,-L_~
1-l_1 new
inlet I I inlet

I~mm 68.

I
1.--324.3
I mm

• The inlet will move about 2.25 inches towards the engine
• The exhaust will move about 7.8 inches away form the engine
• There are about 25.4 mm per inch.

Figure 8. RELITIVE DIMENSIONS; TOP VIEW

DRAWING rme DRAWING NUMBER REVl

Ingersol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C ., SHEt:r 12 OF 28
I ._ " . u_. __. ..... _
Solar-Turbines RETROFIT KIT DRAWING
A Caterpillar Compar.y

5 HYDROMECHANICAL SCHEMATIC

LEGEND
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~ EXTERNAL CONNECTION, REFER TO MECHANICAL INST. DWG.

~ LOOSE SHIPPED FOR INSTALLER INSTALLATION

~ INSTALLER FURNISHED PIPING

~ THESE COMPONENTS/CONTINUATION PTS ARE DEFINED ON FUEL SCH.

~ THESE COMPONENTS/CONTINUATION PTS ARE DEFINED ON LUBE SCH.

DRAWING nTLE DRAWING NUMBER REV. I

Ingersol Rand Starter Change
Vane Type to Turbine Type
176458-0 N/C SHEET 13 OF 28 I
· SolarTurbines RETROFIT KIT DRAWING
A C_~rp;fItr COIfIIJ'IY

'AS We",
&

"000 ~UO[ CI~ 00(;.00

t~
v
.,.,'''1 ""•.,~o
nOlO PI~O'

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------.J~I
~~
P._ E 'I : tl I ( (."C

,It"
&,& &. >1'"'"
..
- ,'
'0010 L~C
&.
OIL CAO(.

Figure 9. VANE TYPE STARTER MOTOR SCHEMATIC

NOTE

LU901-1, IS THE STARTER MOTOR LUBRICATOR USED IN

THE VANE MOTOR APPLICATION ONLY. THERE IS NO LU-
BRICATOR IN THE TURBINE TYPE STARTER SYSTEM.

NOTE

THE 'RH' DESIGNATION, NEXT TO V2P921, IN THE ABOVE

SCHEMATIC, IS IDENTIFYING THE RIGHT HAND PORT.

DRAWING TITLE I DRAWING NUMBER REV.

Ingersol Rand Starter Change 176458-0
Vane Type to Turbine Type N/C I SHEET 14 OF 28
•

. Solar-Turbines RETROFIT KIT DRAWING ~

A CBterpilliJI Company

,., '1-'
&
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-.-. _ .._ ..__ .;T ,_ ~"'I Ol~ w(OO(O

1\ : t • •. &.
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Figure 10. TURBINE TYPE STARTER MOTOR SCHEMATIC

NOTE

THE 'RH' DESIGNATION, NEXT TO V2P921, IN THE ABOVE

SCHEMATIC, IS IDENTIFYING THE RIGHT HAND PORT.

DRAWING TITLE DRAWING NUMBER REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET 15 OF 28
.--.~.-- . ----.- .----------- - ------- _. -
-- -----
Solar-Turbines RETROFIT KIT DRAWING
A Caterpdlat Company

6 SYSTEM FUNCTIONAL DESCRIPTION

NEW TURBINE-PNEUMATIC START SYSTEM

ALL CENTAUR H AND TAURUS WITH P/N190475-100

6,1 GENERAL DE~CRIPTION

The pneumatic start system utilizes a starter motor assembly, with twin turbine pneumatic
motors, to generate the necessary starting torque and transmit it to the engine through a
common overrunning clutch in the accessory gear train. The turbine engine requires
starter assistance until it reaches a self-sustaining 9000 rpm (60 percent) of rated speed.
Thus, engine purge, lightoff and acceleration to 60 percent speed are accomplished with
the aid of the starter motor assembly. When the turbine engine accelerates to 60 percent
speed, the supply of gas or air is shut off to the starter motor assembly, and the twin turbine
motors cease rotation. The overrunnin., clutch then disengages and allows the turbine
engine to accelerate on its own to idle speed.

The pneumatic start system has the following primary components:

• Clutch lubrication fixed orifice

• Inlet gas strainer

• Gas shutoff pilot solenoid valve

• Starter motor assembly

• Gas shutoff valve

The start system uses a nominal supply of 2400 scfm (68 nm3/min) of clean filtered gas or
air at 165 to 225 psi (1138 to 1551 kPa) for the pneumatic power supply. The supply gas
may be delivered from a common source with fuel system gas, using an external manifold.
If a separate source of compressed air or service gas is used, a quick - acting manual shut-
off valve and a strainer must be installed in the gas inlet. Natural gas, when utiiized as the
pneumatic supply, shall conform to the Service Gas Requirements as listed in your oringi-
nal operations and maintenance manual.

6.2 FUNCTIONAL DESCRIPTION

The following paragraphs describe the function of the pneumatic start system. For pre-
scribed limits or values, refer to the Pneumatic Start System Schematic (149635).

Start system pilot gas pressure is supplied and regulated, by a fuel system pressure con-
trol valve, at a nominal pressure of 80 psi (552 kPa). The Gas Shutoff Pilot So.enolo 'Valve
(L330 -1) controls the supply of pilot gas to the Gas Shutoff Valve (V2P921).

DHAWlNG TITLE
In.gersol Rand Sta!1er Change
Vane Type to Turbine Type
I DRAWING NUMBER
176458-0
REV.

N/C SHEET =-=l

Solar-Turbines RETROFIT KIT DRAWING
A Caterpilldf ComptlflY

The gas shutoff valve controls the pneumatic supply to the Starter Motor Assembly
(M922 -1 ). The gas shutoff valve for the starter motor assembly is held in a normally-
closed position by return springs when the pilot solenoid valve is de-energized and no
pilot gas is supplied to its valve actuator.

The pneumatic start system is automatically actuated by the electrical control system dur-
ing the starting sequence. Following a prelube cycle of a predetermined duration, normally
30 seconds, the gas shutoff pilot solenoid valve is energized. Pilot pressure is admitted
to the gas shutoff valve actuator, which opens the valve. The starter motor assembly twin
turbine motors begin to crank the engine.

Cranking continues until 60 percent engine speed is attained, when a signal from the elec-
trical control system de-energizes the pilot solenoid valve. Pilot pressure is vented, and
the compressed springs in the gas shutoff valve actuator close the gas shutoff valve. The
starter motor assembly twin turbine motors are stopped, and the clutch overruns.

NOTE

The prelube cycle is normally 30 seconds. However, depend-

ing on application requirements, it may be longer on some in-
stallations. Refer to the electrical schematic for data applicable
to this set.

DRAWING nTLE
Ingersol Rand Starter Change
I DRAWING NUMBER
176458-0
REV.

Vane Type to Turbine Type N/C I SHEET 17 OF 28

Solar-Turbines RETROFIT KIT DRAWING :=J
A Cate1pl7tat ComPlJTt'l

7 COMPONENT DESCRIPTIONS

Component descriptions are arranged in alphanumeric order by reference designator

number. The reference designator number is within parentheses, and follows the compo-
nent name. Unnumbered components are located at the end of the subsection. For set-
tings and system normal or operating design values not discussed in the following para-
graphs. refer to the Pneumatic Start System Schematic (149635).

7.1 Clutch Lubrication Fixed Orifice

! PIN 141719-2 !

Starter clutch lubrication is accomplished by supplied oil from the lube oil header through
a 0.032 in. (0.82 mm) fixed orifice. A limited flow is assured by the Clutch Lubrication Fixed
Orifice (F0921) to the starter clutch and it ·gears as it feeds.

7.2 Inlet Gas Strainer

!PIN 918629C1 !

The IntetGas Strainer (FS921). installed off-skid, is a cast steel Y-shaped fitting contain-
ing a removable cylindrical screen with 0.033 inch (0.8 mm) diameter perforations. It is
used to filter the incoming start gas. A customer-furnished shutoff valve is required .uP-
stream to permit servicing of the strainer and to shut off the supply during maintenance or
other contingencies.

7.3 Gas Shutoff Pilot Solenoid Valve

!PIN 186269-1

The Gas Shutoff Pilot Solenoid Valve (L330-1), when energized, directs pilot gas pressure
to open the Gas Shutoff Valve (V2P921). De-energized, the pilot valve vents pilot pressure
from the gas shutoff valve actuator. allowing it to close.

7.4 Starter Motor Assembly

!PIN 190475-100 ! J

The Starter Motor Assembly (M922-1). in the starter adaptor housing, is composed of
twin turbine-type pneumatically-operated starter motors. The motors transmit starting
power to the turbine engine through combining gears to a common overrunning clutch and
shaft. Mounted on the accessory drive assembly, the starter adapter housing receives lu-
bricating oil through a Clutch Lubrication Fixed Orifice (F0921) and directs it to the starter
and clutch assemblies.

DRAWING TITLE
Ingersol Rand Sta~ter Change
I DRAWING NUMBER
176458-0
REV.

N..'C 18 28
Vane Type to Turbine Type SHEET OF
I __ . ._
Solar-Turbines RETROFIT KIT DRAWING
A Carerpi/fllf Company

Each starter motor consists of two back-to-back radial inflow turbines on a common
shaft. Partial admission nozzles convert the pressure energy of the supplied gas or air to
velocity and direct it to the turbine blades. The exhaust, from the center of the turbine
wheels, is combined and directed to the aft-end exhaust collector. The high speed of the
turbine rotor is reduced by an internal planetary gearset to a more useable 6000 rpm. Thfs
gearset is lubricated from an internal sump.

7.5 Gas Shutoff Valve

! PIN 186232-400 !

The Gas Shutoff Valve (V2P921) is a two-position, two-way ball valve that controls the
flow of supply line gas to the starter motor assembly. When the Gas Shutoff Pilot Solenoid
Valve (L330-1) is energized, pilot pressure holds the gas shutoff valve open allowing flow
from the air or gas supply line to the starter motor assembly.

The quarter-turn actuator is a double-acting, rack-and-pinion type with captive inter-

nal return springs that are not exposed to the pilot gas. The springs hold the valve closed
and the pilot chamber is vented through pilot solenoid valve when the solenoid valve is de-
energized. When pilot pressure is applied to the valve actuator, force overcomes the clo-
sure springs and opens the valve.

Internally, the valve is a pressure-operated, spring-closed ball valve. Spring tension

keeps it in a closed position. When the pilot solenoid valve is energized, pilot pressure is
applied to the gas shutoff valve actuator, forcing it open. The gas shutoff valve remains
open as long as pilot pressure is available and the pilot solenoid valve is energized. -

DRAWING TITLE DRAWING NUMBER REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET 19 OF 28
L--- . . ._. . _
-,-----
.' .
-
Solar-Turbines RETROFIT KIT DRAWING
A C«erpillM CompMl'f

8 OPERATIONSMAINTENANCE

8.1 Starter Motor Assembly

The Starter Motor Assembly (M922-1) contains twin turbine-type, pneumatically-oper-

ated starter motors and a gear case. The instructions in this section can be used for either
starter motor. Corrective maintenance of the starter motors is limited to only its removal
and replacement. Maintenance of the gear case is limited to replacement of the coupling
or the gear case assembly.

REMOVAL OF PNEUMATIC STARTER MOTOR

- Ensure that gas supply to starter motor is turned off.

- Remove bolts from split flange clamps retaining inlet and outlet piping to starter
motor.

- Remove split flange clamps.

- Remove inlet and outlet piping from starter motor to be removed. Move piping as
required to provide working room.

WARNING

Starter motor weighs approximately 50 Ib (23 kg). To avoid

Injury, ensure that adequate rigging/support is used.

• Attach appropriate rigging/support to starter motor.

• Matchmark adjacent areas on starter motor housing and gear case.

- Remove capscrews and washers from starter motor housing.

NOTE

It may be necessary to dislodge starter motor housing by tap-

ping with a plastic mallet.

- Pull starter motor aWayfrom gear case.

DRAWING TITlE DRAWING NUMBER REV.

Ingl~rsol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET 20 OF 28
---- - -------
..
Solar Iurblnes RETROFIT KIT DRAWING
A Carerpil!d1 Company

REMOVAL OF GEAR CASE

• Remove both starter motors as described in REMOVAL OF PNEUMATiC START-

ER MOTOR (above).

• Remove four bolts and washers securing oil drain hose flange to bottom of gear
case. Cover open end of oil drain hose .o prevent oil contamination or spills.

• Support gea:- case to prevent it from falling during removal.

• Remove two sets of attaching hardware from bottom front of gear case.

• Remove four sets of attaching hardware securing gear case mounting flange to
turbine accessory drive gearbox.

• Carefully remove gear case by pulling straight out. Remove and discard gasket.

• Remove coupling from driver gear.

CLEANING AND INSPECTION

• Thoroughly clean all parts, and examine for damage, corrosion, and general con-
dition.

• Inspect rotor bearings for binding, excessive wear, damage, or corrosion. Re-
place starter motor if necessary.

INSTALLATION OF GEAR CASE

• Install coupling on driver gear of gear case.

• Install gear case gasket.

• Support gear case in place during installation.

• Loosely install four sets of attaching hardware to secure gear case mounting
flange to turbine accessory drive gearbox.

• Install attaching hardware and torque to standard torque values.

• Connect oil drain tube to oil drain outlet at bottom of gear case. Torque attaching
hardware according to standard torque values.

DRAWING TITLE DRAWING NUMBER Rev.

Ingersol Rand Starter Change
Vane Type to Turbine Type
176458-0 N/C SHEET 21 OF 28
Solar-Turbines RETROFIT KIT DRAWING
A CIII~JI.Jt ComPlJIlY

INSTALLATION OF PNEUMATIC STARTER MOTOR

WARNING

Starter motor weighs approximately 50 Ib (23 kg), To avoid

injury, ensure that adequate rigging/support is used.

• Attach appropriate rigging/support to starter motor.

• Align matchmarks on starter motor housing and gear case.

• Align pinion splines with drive gear splines and push starter motor into gear case.

• Install capscrews and washers through starter motor housing cover.

• Connect outlet hose to starter motor with split flanges and bolts.

• Connect inlet hose to starter motor with split flanges and bolts.

• Repeat Steps 1 through 6 (above) for second starter motor, if required.

• Perform static/operational test(s) as required.

8.2 Inlet Gas Strainer

Maintenance is limited to removing and cleaning the screen.

DRAWlNG TITlE DRAWING NUMBER REV.

Ingersol Rand Starter Change 1'16458-0 N/C SHFET 22 OF 28
Vane Type to Turbine Type
· ~ Solar Turbines RETROFIT KIT DRAWING
A Cllferpil/Il( Comptlly

9 CALIBRATION AND SETUP

• The start gas supply pressure should be between 165 & 225 psig.

• The start motors require 5.33 ounces or 157.6 em3 of Dextron 2 Automatic Trans-
mission Fluid. Clean Turbine oil is an acceptable substitute.

• Start times will depend on the control system purge cycle and the starter gear set.
It should be siginificantly different than the Vane type starters; when new.

DRAWING rms
Ingersol Rand Starter Change
I DRAWING NUMBER
176458-0
REV.

Vane Type to Turbine Type N/C I SHEET 23 OF 28

 ••••

a .' ~
Solar-Turbines RETROFIT KIT DRAWING .."J

A~~

10 SITE MANUAL UPDATE

NOTE

It is reccomended that the following sections of this kit be re-

moved and incorporated into the site Operations and Mainte e

nance manuls.

• Hydromechanical Schematic

• System Functional Description

• Component Descriptions

• Operations Maintenance

• Service Parts List

• Supplemental Data

DRA'M;~G TITlE
Ingersol Rand Starter Change
I DRAWING NUMBER
176458-0
REV.

VaneType to Turbine Type N/C I SHEET 24 OF 28

4

•
SolarTurbines RETROFIT KIT DRAWING
A ClItttpiIII ea.,..y
11 SERVICEPARTSLIST

PART NO. DESCRIPTION QTY..

965213C1 ~ket(spK)Olp~) 2ea
903732C1 O-ring (splitflangeexistingInlet) 4 ea
230275-1 Gasket(starterexhaust) 2 ea
90324901 O-ring (splitflage,exhaust) 2 ea
190475-1 Startmotor,Turbinestyle 2 ea
190475-3 Exhaustelbow 2 ea
190475-2 CombiningGearBox 1 ea

DRAWING T1TlE DRAWING NUMBER REV.

Ingersol Rand Starter Change
Vane Type to Turbine Type 176458-0 N/C SHEET 25 OF 28
 Cl010~ Cl31ClV1S3dAl 3NVI\ ·U 9Jn6!:1

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•• I I ,

Solar-Turbines RETROFIT KIT DRAWING

A Caterpillar Comp8lly

DIMENSIONS IN MIWMETERS UNLESS OTHER\'JISE NOTED

I
H'~
I :2'
&. \..j I
I: 267_' 424
.

"- ---' .1
¢ ICl FOIl ~-I~'
...
H>
PIPE 1SU'-0fc rtPHl.AA:;E)

I SOl-------

NOTE:
:15.7...,,- E> In'I)X'211 Ttf£AO
./ ,IS" ex£.'. 4 I'\.ACt~

:?:-. DENOTES REQUIRED ENGliSH DIMENSIONS I

lUG I
I. DIMENSIONS WITHOUT TOLERANCE AAE.FaA I 61.1)
REfERENCE ONL'! 1
&. FAA SIDE LOCATION Of IM.£ r POfH

e-, QS I S·
c- fipt; is lee fLA'C(

Figure 12, TURBINE TYPE STARTER MOTOR

DRAWING TITLE DRAWING NUMBER REV.

--
lnqeracl Rand Starter Change
Vane Type to Turbine Type
176458-0 N/C SHEET 27 OF 28
I
 4

-.-------
•
. •..
~
Solar-Turbines RETROFIT KIT DRAWING
A CtItttpiJkr C«rtp.ry

13 REVISIONS

RELEASING
REL REV DATE L>OC'JMENT(S) REVISION APPROVAL REVISION DESCRIPTION

@ nc 6-7-93 10884-1 Tim Clayton Initial Relase

-
 '>'

.::; -: v

Ge,'!C'fJI Information
DISASSE:\1BLY OF THE STARTER
o V;
I. Always mark adjacent parts o n the Motor Housing Cover (:::). \lotor Housing (I) .md Gear Case (::;3) so these members
can be located in the same r e la i ive position when the Star t e r is reassembled.
..,
Do not disassemble the Starter any further than necessary to replace a worn or damaged part
0,) not remove any part which is a press fit in or on a subassembly unless the removal of that part IS necessary for rc-
placement or re pair s,
-+. Always have J complete set of vanes, seals and a-rings on hand before starting any overhaul of Starter. "lever reuse old
seals or a-rings.
5. 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.
Motor Housing
I. Unscrew and remove the Motor Housing Cover Cap Screws (4) .
.., Pull the Motor Housing Cover (:2 ) from the Motor Housing (I l, It may be necessary to dislodge the Motor Housing Cover
by tapping it with a plastic hammer.
3: Tap the Gear Case (23) with a plastic hammer to dislodge it from the Motor Housing.
4. Grasp the Rotor Pinion (:::0) in a vise and using a wrench, remove the Rotor Pinion Retaining Screw (J 9).
5. Remove the Rotor Pinion from the rotor shaft.
6. Slide the Front End Plate (J 6), Front Rotor Bearing (18). Bulkhead (21) and Motor Wave Washers (17) off rotor shaft.
7. Remove the Rotor (13) and Rear End Plate (9) from the Cylinder.
S. Remove and examine each Vane (15). Install a new set of Vanes if any Vane is cracked, spalled or worn to the extent
that its width is IS! 16" (24 mm ) or Jess at either end.
9. Grasp the Rotor in a vise. USing a 5/32" (4 mm) hex wrench. loosen the Rotor Clamp Nut Screw (14). Unscrew and
remove the Rotor Clamp Nut (i::; j.
10. Remove the Large Rear Rotor Bearing a-ring (11 )
II. Remove the Rear End Plate (9! from the rotor shaft.
12. Remove the Small Rear Rotor Bearing a-ring (lOA) from the rotor shaft.
13. If the Rear Rotor Bearing (l 0) needs to be replaced, remove it from the Rear End Plate.
14. Push the Cylinder (5) out of the Motor Housing.
15. Remove the Cylinder a-rings (3) from the Cylinder.
Gear Case
1. With the Gear Case (23) facing up, the Drive Gear (25) should be visible.
" Remove the Retaining Ring (29) from the Shaft (24).
3. Using a gear puller. remove the Drive Gear.
4. Remove the Retaining Ring (28) from the Drive Gear. ..•
5. Remove the Bearings (26) and Spacer (27).
6. Using a hex socket, remove the Shaft from the Gear Case. NOTE: These are left-hand threads.

ASSEMBLY OF THE STARTER

General Information
I. 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 in a bearing recess.
3. Whenever 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.
4. Always clean every part, and wipe every part with a thin film of oil before installation.
Motor Housing
I. Clamp the Rotor (13) in a vise, threaded end up.
2. Install the Rear Rotor Bearing (10) into the Rear End Plate (9).
3. Using a-ring lubricant, lubricate and install the Small Rear Rotor Bearing Ovring (lOA) onto the rotor shaft until it
butts against the rotor shaft shoulder.
4. Install the Rear End Plate (9), bearing end up, onto the rotor shaft.
5. Screw the Rotor Clamp Nut (12) onto the rotor shaft WIth the shoulder toward th:! bearing. Tighten the nut until there
is .001" (.02 mm) to .003" (.07 mm) clearance between the Rear End Plate and Rotor.
6. Using a 5/32" (4 mm) hex wrench, tighten the Rotor Clamp Nut Screw (I~) to 8 ft-lb (l0.8 r..; m) torque. Recheck the
clearance between the Rear End Plate and Rotor, after tapping the End Plate away from the rotor face with a plastic
hammer.

4
 7. Check the two End Plate Alignment Pins (6). If they are bent or broken, remove them from the Cylinder and press in a
new pin or pins.
8. Check the Cylinder Alignment Pin (7). If it is bent or broken. remove it from the Cylinder and press in a new pin.
9. Using Ovring lubricant. lubricate and install the two inside Cylinder Ovnngs (8).
10. Position the Motor Housing (I) vertically. on two blocks of wood. locating slot up.
__
- II. Using a plastic hammer. tap the Cylinder (5) into the Motor Housing making sure the Cylinder Aiignment Pin (7) seats
into the slot of the Motor Housing.
12. Using Osr ing lubricant. lubricate and install the two outside Cylinder Ovrings (8).
13. Insert the Rotor (13) into the Cylinder. pinion end toward the Cylinder Alignment Pin. NOTE: Make sure the protrud-
ing End Plate Alignment Pin (6) in the Cylinder aligns with the dowel hole in the SS800L·12 Rear End Plate (9). Make
sure the air ports of the Cylinder and the Rear End Plate align.
14. Lightly lubricate each Vane (15) and insert one in each of the rotor vane slots.
15. Slide the Front End Plate (16) over the pinion end of the Rotor. The other protruding End Plate Alignment Pin (6)
in the face of the Cylinder should align with the dowel hole in the Front End Plate.
16. Insert the two Motor Wave Washers (17) into the Front End Plate well.
17. Install the Front Rotor Bearing (18) into the Front End Plate well.
18. Press a new Seal (22) into the Bulkhead (21). The Seal should be pressed in from the chamfered side of the Bulkhead
with the lip of Seal facing the motor.
19. Install the Retaining Ring (21 A).
20. Grease the seal bore with a good quality grease. Very carefully work the Rotor Pinion (20) into the Bulkhead/Seal
Assembly.
21. Install the Rotor Pinion on the rotor shaft so that the lugs on the Pinion engage those on the shaft.
22. Screw the Rotor Pinion Retaining Screw (I 9) into the rotor shaft and tighten to 90 ft-lb (I22 N m) torque.
Using Ovring lubricant,lubricate and install the Rear Rotor Bearing Ovring (11) onto the Rear Rotor Bearing.
Set the Motor Housing Cover onto the Motor Assembly. Carefully tap the cover onto the motor. Check for proper
orien ta tion.
25. Check freeness of the motor by turning the Rotor Pinion. If necessary, tap the Front End Plate with a soft hammer to
align the motor.

Gear Case
l. With the Gear Case (23) facing up (the large single bore), install the Drive Gear Shaft (24). Tighten to 150 ft-lb (203
N m) torque. NOTE: These are left-hand threads.
2. Insert one Drive Gear Beanng (26), Spacer (27) and the other Drive Gear Bearing (26) into the Drive Gear (25).
3. Install the Retaining Ring (28).
4. Press the Drive Gear Assembly onto the Drive Gear Shaft and install the Retaining Ring (29).

.~
TORQUE CHART
Illustration Number Part Number Assembly Torque Sealant Required

'" 3 HSPPS·3 30 ft-lb (40.7 N m) No>

4 SS800·25 60 ft-lb (81.4 N m) No
14 SS800·63 8 ft·Ib (10.8 N m) No
19 WE205·817 90 ft-lb (122 N m) Yes, under head
24 SSI600-8 150 ft-Ib (203 N m) No
31 SS16OO-182 45 in-lb (5.1 N m) No

·Part Number HSPPS-3 has pre-applied sealant.

5
 . .-

-
 (
( \

PART NUMBER FOR ORDERING f PART NUMBER FOR ORDERING -.

2
Motor Housing (with 2-1/2" SAEJ518C
Flanged Exhaust)
Motor Housing Cover (with 1-1/2"
. SS800-140 1
:1
i8
19
20
Front Rotor Bearing ........
Rotor Pinion Retaining Screw .. _ .........
Rotor Pinion (2) .....................
_ ......... SS800-22
WE205-817
SS1600K-17C
,SAEJ518C Flanged Inlet) . SS800-A202 21 Motor Bulkhead (2) ..................
4 I
Motor Housing Cover Cap Screw (4)
4A Motor Housing Cover Cap Screw
. SS800-25
I
21A Retaining Ring (2) ...................
SS1600-150
SSI600-270
• 22 Bulkhead Seal (2) ....... _ ............ SS1600·151
Washer (4) _. . . . . . . SS800-26 23 Gear Case ......................... SS1600-37
5 Cylinder Kit _. . . . . . . . . . . . . . SS800-K3 24 Drive Gear Shaft. ... _ ................ SS1600-8
6 End Plate Alignment Pin (2) . . . . . . . . . . . SS800-98 25 Drive Gear. ........................ SS1600K-9C

•
7
8
Cylinder Alignment Pin . . . . . . . .
Cylinder a-ring (4) _. .
.
.
.
.
.
.
.
.
.
.
.
.
SS800-99
SS800-67
• 26
• 27
Drive Gear Bearing (2) .................
Bearing Spacer ............•..........
G7-24
SS1600-265
-..J
9 Rear End Plate. SS800L-12 28 I Bearing Retaining Ring ................ SS1600-366
• JO Rear Rotor Bearing.·. . . . . . . . . . . . . . . . . . SS800-24 29 Shaft Retaining Ring. _ ................ 5S1600-179
• lOA Rotor Shaft a-ring _ C321-606 30 Coupling .......................... SS1600-181
• II Rear Rotor Bearing a-ring, . . . . . . . . . . . . . HRA20A-990 31 Shoulder Screw ..................... SSI600-18::
12 Rotor Clamp Nut. . . . . . . . . . . . . . . . . . . . SS800-65 .•. Nameplate ......................... SS800-301
- J3 Rotor. . . ._. ,~ SS8:fr.5-53 .•. Nameplate Screw (4) .... _ ............. R4K-302
14 l1totor Clamp Nut Screw. . . . . . . . . . . . . . . . SS800-63 .•. Relay Valve (2) _ .. _ ...... _ .......... SRVI50SS
• 15 Vane Packet (set of 5 Vanes) . . . . . . . . . . . . M800-42-5 .•. In-Line Lubricator (2) ................. NL-24-8
16 Front End Plate ~ c,RoOG-ll .•.
,. Starter Control Valve ................. SMG-G618
17 Motor Wave Washer (2) . . . . . . . . . . . . . . . . SS800-224 i Pressure Ga uge ..................... _ SS825-1064
L--. _~
I _ iI i __ .

.•. Not illustrated .

• To keep downtime to a minimum, it is desirable to have on hand certain repair parts. We recommend that you stock one (pair or set) of each part indicated by a
bullet (e) for every four tools in service.

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