03537651 Form P6921 Edition 10 February, 1998 INSTALLATION AND MAINTENANCE MANUAL for Wartsila SERIES ST700 TURBINE-POWERED STARTERS IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS MANUAL BEFORE OPERATING TOOL. FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY. + For safety, top performance, and maximum * Caution should be taken when operating these durability of parts, do not operate Series ST700 starters on gas because of the danger of fire, Starters at air pressures over the pressure rating explosion, or inhalation. After assembling a starter, stamped on the nameplate. Use supply lines of always test it in accordance with the procedures adequate size as directed in the installation outlined in this manual. Never install a reassembled instructions in this manual, starter that has not been tested in accordance with + Always turn off the air or gas supply and iis preasieras is ie eset disconnect the air or gas supply hose before * Operate this start ‘when properly i on installing, removing or adjusting any accessory on Qberate this starter only when properly installed . the engine. this starter, or before performing any maintenance onthisstates any + Donot lubricate starters with flammable or volatile + Series S700 Starters are designed for gas liquids such as kerosene or jet fuel. operation. They are not totally sealed in dynamic + For personal protection, do not remove any labels. operation since the exhaust must be vented or piped Replace any damaged label. away and there is a possibility of leakage around + Use only recommended Ingersoll-Rand accessories. the output shaft when rotating. ‘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 Servicenter. Spec test as, when apical can be found in he Speci Tistrction Seton hs manu 1s the respnstty ee empleyer to place thenfrmation nhs manne the hands the eperstoe Retr Al Commonzatos to he Near Inger Rand Otero Diseuise INGERSOLL-RAND. Ogee Rand Conpery se ——___ Printed in US.A. ENGINE STARTING SYSTEMSWARNING LABEL IDENTIFICATION 7 Wie} FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY. & WARNING this starter. Always wear eye protection when operating or performing maintenance on on this starter. i] adjusting any accessory on 2 this starter, or before performing any maintenance pot 4 WARNING ‘Always wear hearing protection when operating this starter. WARNING cyv2 Always tum off the air supply and disconnect the air supply hose before installing, removing or May & WARNING Do not use dat fray or deteriorated air hoses and fittings. NOTICE For natural gas operation, starter main exhaust must be piped away. ‘To pipe the Drive Housing vent, remove the Drive Housing Plug and replace it ‘must vent at a safe location and must not be interconnected with any other exhaust Pressure on the Drive Housing Vent. NOTICE suitable tubing line. The tubing which might introduce a baes 'S1900-267 Strainer or equivalent is required for all starters used in GAS applications.CONTENTS Page Installation Mounting Dimensions Piping Diagrams .. How to Order aM Detailed Illustrations . cose 15,1619 Parts Listing ......... . = 17-18, 20-23 Exhaust Kit Disassembly ... Assembly .. ‘Testing the Starter ....... ‘Troubleshooting cesses 36,37 Index .... 38PLACING THE STARTER IN SERVICE INSTALLATION For maximum performance, read this manual prior to the installation or operation of Series ST700 ‘Tarbine-Powered Starters. General Information 1. Its strongly recommended 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 startet. 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 atthe inlet. ‘The furnished Flange Mounting Kit is required for installation. All piping, hoses and valving must be clean prior to installation. Make sure thatthe 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 starter end of the hose handy for attaching to the starter. 4, Engine design often demands that the starter be ‘mounted underneath in extremely close quarters, and even though two of the mounting bolt holes are easy to reach, the third one is often less accessible. To install a starter, the following tools are required: regular ratchet wrench, sockets, universal joint, socket extension and a single of double-end box wrench. ‘5. The efficiency of an Air Starter can be greatly impaired by an improper hook-up. Hoses smaller than those recommended will reduce the volume of air to the ‘motor and the use of reducers for piped-away applications in the exhaust port will restrict the exhaust causing back pressure to the motor resulting in reduced performance. The number of tees and elbows, and the Jength of the supply line should be kept to a minimum. Use 1-1/2” hose or pipe for supply lines up to 15 feet Jong; use 2” hose or pipe if the supply line is over 15, feet long. 6. A leak in any of the connections in live air lines means thatthe system will drain overnight and will have to be re-pressurized 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. SMB-441 Sealant, non-hardening No. 2 Permatex or Loctite®* Pipe ‘Sealant. Afier 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. Always run the air supply line from the side or top of the receiver, never at or near the bottom. Moisture in the air collects at the bottom of the receiver resulting in ‘damage which could cause the valves to become inoperative. Periodically open the petcock at the bottom of the tank to drain the water. ‘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. We recommend installation of a “glad hand” for -mergency 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 a pipe plug can be mated to it, ora “glad hand” protector bracket can be used. . It is required that a strainer be installed in the inlet Tine for each starter. Ingersoll-Rand offers 5 strainers: ‘ST900-267-24 for 1 172 inch lines, ST900-267-32 and ST900-267-32F for 2 inch lines, ST900-267-48 for 3 inch lines and ST900-267-66 for 4 inch lines. ‘These 300 mesh strainers provide 50 micron filtration ‘and offer significant protection against supply line contaminates which could damage the turbine components, Replacement elements are ST900-266-24 for 11/2 inch, ST900-266-32 for 2 inch pipe thread, 'ST900-266-32F for 2 inch flange, ST900-266-48 for 3 inch flange and ST900-266-64 for 4 inch lines. Orientation of the Starter tis recommended that starters be ordered to proper ‘rientation for your specific mounting to the required engine or for your specific installation, However, ifthe starter must be reoriented for installation, proceed as follows: |. Refer to the dimension illustration on pages 7, 8 and 9 and note that the Drive Housing can be located in any ‘one of sixteen radial positions relative to the Gear ‘Case and the air inlet can be located in any one of fou \ radial positions relative to the Drive Housing. . Study the engine mounting requirements, and determine the required orientation of the Drive Housing relative to the Gear Case. Ifthe 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 the Drive Housing Cap Screws and tighten o 28 ft-Ib (38 Nm) torque. . 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,PLACING THE STARTER IN SERVICE Nous 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 alternately tighten them to 60 ft-Ib (81.4 Nm) torque {in 20 ft-lb (27 Nm) increments. ‘Mounting the Starter 1. Study the appropriate piping diagrams on pages 10, 11, 12 and 13 and install as indicated. 2. ‘The air receiver tank for a starter installation must have ‘a working pressure rating equal to or greater than the ‘maximum pressure at which the starter will be operated. 3. When connecting the starter to a receiver tank that is service, bleed off the air pressure in the tank stalling the starter. A WARNING 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 he SRV150 Starter Relay Valve on the end of the receiver tank as shown in the piping diagram. 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. ‘5. For air installations, install the Starter Control Valve (SMB-618) on the dash panel (for vehicular stallations) or some other appropriate pane! (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 (150BMP-1051B) securely and preferably in a vertical position away from any concentration of heat, vibration or contamination. Connect the leads to the ‘operator's starting switch which should be located on the dashboard or control panel 6. Attach Starter Instruction Label (TA-STR-100) to the control panel adjacent to the Starter Control Valve. 7. Mount the Air Pressure Gauge (150BMP-1064) on or adjacent 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. 10. nh. 2 13, 14. 15, 7. NOTICE ‘Make certain the hose is connected to the supply side (marked “SUP”) of the Starter Control Valve. To determine the exact ength 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. 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 atthe starter location. At this point, determine whether or not it is feasible or practical to attach the bose to the starter before or after the starter is actually mounted. In many cases it may be necessary to attach the hose tothe starter before mounting. Uf possible, liberally grease the teeth on the ring gear ‘with a good quality sticky gear grease. This will help promote the life of the ring gear and the starter Pinion, ‘Move the starter into position, and mount it on the ‘lywheel housing, Tighten the mounting bolts to 100 ft-1b (136 Nm) torque. For Pre-Engaged Models, install a 1/4” hose line from the delivery side (marked “DEL") ofthe starter ‘Control Valve or Solenoid Valve to the “IN” port on the Starter Drive Housing. NOTICE Inadvertent application of air pressure to the “OUT” port will result in Drive malfunction (Pinion will fail to retract). If this condition occurs, loosen Drive Housing Cap Screws (38) to vent Gear Case (28). Also, loosen Housing Plugs (10) and (11) to vent Motor. 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. Ifthe 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. 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 connections,PLACING THE STARTER IN SERVICE 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 Series ST700 ‘Turbine Starter. 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 access to the hole at the center of the Housing Exhaust Cover. Remove the 1/4” pipe plug. For Models with Inertia Drive: |, Manually engage pinion and insert a 1/4” hex ‘wrench through the hole in the Housing Cover to ‘engage the hex drive recess atthe rear of the Motor Assembly. 2. Manually rotate the Motor Assembly until the engine is cranked to the desired position. For Models with Pre-Engaged Drive: 1, Disconnect the 1/4” hose at the “OUT™ port on the Drive Housing, and plug the hole in the Drive Housing with a 1/4” pipe plug. 2. Engage the Drive Pinion with the flywheel by applying a minimum of 70 psig (4.8 bar/483 kPa) to the “ port on the Drive Housing. 3. Insert a 1/4” hex wrench through the hole in the Housing Exhaust Cover to engage the hex drive recess in the rear of the Motor Assembly. 4. Manually rotate the Motor Assembly until the engine is cranked to the desired position,'ST700 INERTIA MOUNTING DIMENSIONS PLACING THE STARTER IN SERVICE (Dwg. TPA1276~4)PLACING THE STARTER IN SERVICE (s-uz1vas ‘Bma) tessa us 1009 “BOON PERE T wg Pe OTT ‘SNOISNAWIG SNILNNOW$T700 PRE~-ENGAGED MOUNTING DIMENSIONS PLACING THE STARTER IN SERVICE (Owg. TPA1278~4)PLACING THE STARTER IN SERVICE PIPING DIAGRAMS PRE-ENGAGED SYSTEM (SERIES ST700 SHOWN) Typical Vehicular installation srynten congo vave ‘Sie 618 B55) SM@OID VALVE -12 voLT 121 LEN To orenATORS 5 ARE!O YN Thanh ono eA BiclOneron wer we.7. BI SY cr RIE Hous No Sent age We" Neer, bat baer cunce KIT ASTVOO-RIBS™ retay vue 1 172" «Sito unt PIPE RMINAYALYE 17270 LA" NPT. PRESSE MEASIRING, 26, epentring. Bessune NOt TO ExCEED HA PRESSE RATING SIAIPED Ov STARTER NAMEPLATE, Typical Stationary Installation stare sexier vue, SteD0"ee7-24 fort ect htar oe ea pose ary SINTER compan, vv 4 38.518. (oS AIR PRESSURE Gx ‘i661 TCHR ZSAS) ve lofetesfoae CAIRO 2g 37. pONPIER 74 PAT i sa nose"), RETOUR Seeanee See Wa se C eS Lay VLE 1/2" ‘Svs Worretge + 70" haber ExELEO ua PREScuRE RATING STAMPED ON STARTER RAKEPLATE, rreshine mean arc > SRESaRE Farin stom ON 1/4" WPT, PRESSURE MEASLAN 7 ‘Staten MAuEPCATED H6ai_"eeniring. eeesstneto"t0 A is Stmowo wich pressure syste AP OB tee peeaeine fea MEW Suen Hrescire Te oleh "Eonar. cas OPERATION, sranTER WAN EMIT MST BE 1 INGERSOLL-RANO PART NICER Five Mo rertacesWeni thea Sur He foene Chee SSI THe TUBING Misr vENTTAT acAre COCATION MO WT NOT BE Inencomecteo wit sky Greer chadst tine witen AlgaT intncouce™n ‘atx res Ov Te Oe OSI (Dwg. TPA1282-3) 10PLACING THE STARTER IN SERVICE PIPING DIAGRAMS INERTIA TYPE SYSTEM (SERIES ST700 SHOWN) Typical Vehicular Installation Saewoio vave 12 VOT (2) LENDS 10 operarons 4, SRENBIO YAY Santing HTT STARTER conte. vaLve Fe Sis 81S RAGE cae AIR ERESSURE. GAGE otaentiiaaa coptions. comma Cipeurr une zing ELECTRIC SiceNoIb CONTROL VALVE ND PRREL MOUNTED SHT The Dieer Lance Kit 31760 08. sear aie 117 & SRVISO = Lae PIPE Ma" WPT PRESSURE MEASURING FORT. Aeialife eeeSSire tote Bees SSRN Te inti erat Menthe: vores ne Sean Seine aa Typical Stationary Installation seit ye S8SEy-20 Heove eGo eeiing om GAS oPemarion, Tee: Fever vacve ourtr Mist BePIPED aay TOA Sire LeAT TOW. nap pressure once {sbote Toba AIR oxLy io Ressune Supt eer Fuanoe KIT se S760: RTS Riso Ve atten cowrea, vaive 6-818 nse SiB6-o1e Tore CAs) Staaten NEMRTE Ia" WPT. PRESSURE MEASLEING PORT. ‘elie oa Soe rue [a> wore Sete eos USE SEALANT. NAMEPLATE. Baer oust +e ‘e INGERSOLL -RAND PART NUMBER ea FOL NATURAL GAS OPERATION, STARTER MAIN BOAUST MUS PRS WR: T MST Of TEI TE OE ste vex, oe ne ene asi AOR IE te var, aang oe IRE ei Sl hl 08 Bh" oF HGPRT Ra" REPS Biche (Dwg. TPA1283-3)PLACING THE STARTER IN SERVICE PIPING DIAGRAMS PRE-ENGAGED SYSTEM (SEHIES. ST700 SHOWN) ‘Typical Installation with Engine Prelube System when ‘Gupply Pressure is over Rated Starter Pressure OL. PRESSURE SENSING VAL RELIEE YALE spngynve 1 vee Baga poe gs emia me le ssese ver SM Elevates SeeCie pearyowran \ cue: soern ve weer. woe mesure spr Viet PTS Sess 2IC_37* ADAPTOR 1/47 N.P.T= Ses tit EB : 6 ents Se alee taint os ea ea surety || SES PAINS. SHOWN ON STARTER RAKCPLATED es ose 1 ar eT . " SEE HOSE L174") 24> eT ESSURE FORLAATURAL GAS OPERATION, STARTER MAIN EnWUGT WAST Be Tez Ne oe ye vr, foe ne ne vLse FSS HEU se, ANS rye Restate tan er ees ease UEPHRSDE RET AEDES MeN * suanen coum. VAL Stereisiornss! ee aera er gees Seheeen ences Bonen eee y JIC 37+ ADAPTOR 1/4" N.P.T. SREB. Cae wT 7 {lek ie wnvue te SRVISO ee (Dwg. TPA1281-3) 1% INGERSOLL-RAND PART MAMBER ** FoR NATURAL GAS OPERATION, STARTER MAIN EXHAUST IST BE Tmaynse Vae.s. Sg + BLURS ve TPs on mame vor, Rane ne one ve Sanne AR Be PUL BAPE ee Beye Bean dir ant ar So BS wr “a HARE EE RPE a ew VENT, y 12PLACING THE STARTER IN SERVICE (r-vezt vd *6M0) onisnon sy1u0 aH No sense 2ove sins. weet 3th SE ayy _335 Bas adie abst) 350m 4 Lat 1 3508 He uopEEysU) LeLES WN FeOyAAy BPLACING THE STARTER IN SERVICE Series ST700 Turbine-Powered Starters are designed for air or gas operation in off-highway, marine and stationary applications. HOW TO ORDER A STARTER NOOEL COOTNG- EL ane Ta s7 moporana- on wor SS [anos [Bae Poor] S| STTSOSOTOSRTT [S507 034 [P06 266-1 78 [sTrsossoToase|= |isori034 | 2oau-200-3 8 [st7@8600 103831 | Sy] _oove21 = 290 68 [stroeceor0a | g8| soveet —|2oeu-2s0-a] 1272 Lave tere srecirien mex cen (Owg. TPD1176) =WODEL COOING= are [__Piniow ona S77 ep 0PoaR 3-06 woe. Fiero al ae scone | [Ear on STSOGSOPORART] | 1807104 7a. ces a STs [lav 8 coon narios £2 vow igs trans or | [sr7soscpe0a5| © fisoria3e oe. ey rorarion PIAA | Te TrSoesopoa 26] 8 [1so7i034 578 Freer mneranve) Lime sowerne ruse STresceorosral| = | 90/621 a stresceoroa.s2| 5 | 90/621 oe 'srresccorosnas| © | s0ve21 a stresceoroa.z6| 8 [o0vear [i212 Lore Cvest oe srecirieD wen orcERINS (Owg. TPD1177) -WODEL CODING SUPPLY | PINTGN DATA SIZE staRTER J] Re SING |__Nooet. [TEETH P-P4 gS" |PA oa : pumiee wae | (St7SocooposAS1B |150/i034|" 15 |67a|2.507[20 mre, ccie Case | | [Lnorarion’ “PimaHBATS | [ET 7S0GDOPOaLS2 Ee [15071034 | 15 _|67a|2,50420: THE MOUNTING FLING rrescooroes| yf sovezi_| 1S —lerale.soyzo MUST BE SPECIFIED WHEN ORDERING (Dwg. TPD1178) For different models or spectal applications, contact you nearest Ingersoll-Rand Distributor or SALES HEADQUARTERS, Engine Starting Systems, P.O. 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