',l:

t '
; l 'Q3539319
Form P7061
Edition 2
INSTALLATION AND MAINTENANGE'MANUAL
for
MODEL ST400 TURBINE POWERED STARTER

(
!A, WARNING
IMPORTANT SAFETY INFORMATION ENCLOSED.
READ THIS MANUAL BEFORE OPERATING STARTER.
FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY.
• For safety, top perforntance, and maxin1un1
durability of parts, do not operate ST400 Starters
at air pressures over the pressure rating stamped
on the nameplate. Use supply lines of adequate size
as directed in the installation instructions in this
111auual.
• Always turn off the air supply and disconnect the
air supply hose before installing, removing or
adjusting any accessory on this starter, or before
performing any maintenance on this starter.
• Operate ModerST400 Starters on compressed air
only. They are not designed or sealed for operation
on contpressed gas.
• After assembling a ST400 Starter, always test it in
accordance the procedures outlined in this manual.
Never install a reassembled starter that has not
been tested in accordance 'vith the procedures
outlined in this manna!. This manna! should be
filed in a permanently available location.
• Operate this starter only when properly installed
on the engine.
• Do not remove any labels. Replace any damaged
label.
• Use accessories recomntended by Ingersoll-Rand.

NOTICE ,"
The use of other than genuine Ingersoll-Rand replacement parts may result in safety hazards, decreased starter
performance and increased n1aintenance, and may invalidate all \varranties.
Ingersoll-Rand is not responsible for customer modificatiou 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.
It is the responsibility of the employer to place the information in this manual into the hands of the operator.

Refer All Communications to the Nearest

Ingersoll-Rand Office or Distributor. INGERSOll-flAND@
© l11gersoll-Ra11d Company 1997
Printed in U.S.A. ENGINE STARTING SYSTEMS
 WARNING LABEL IDENTIFICATION

.~WARNING.
'~ "
~ ~

FAILURE TO OBSERVE THE FOLLOWING WARNINGS COULD RESULT IN INJURY. (

,A WARNING ,A WARNING

®
Always wear eye protection when Always wear hearing

•
performing maintenance on this protection when testing this
starter. starter.

'

:;
• WARNING
Always turn off the air supply and
I

v/~~
~
I
1ri ~1 I
)
,A WARNING
Do not use damaged, frayed or

I"'~
deteriorated air hoses and
disconnect the air supply hose
before installing, re1noving or ~ fittings.
II adjusting any accessory on this
. .. II starter, or before perfonning any
maintenance on this starter.

2
 CONTENTS

Page

HOW TO ORDER THE SYSTEM

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5

Composite Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

System Components ............................................. , . . . . . . . 6-8

Fittings ................. ; ......................... ·... ; ........ ; ........ ; . 7-8

( PLACING THE SYSTEM IN SERVICE

System Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation I Piping ..................................................... 10, 11

Composite Tank Compression Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 O

Dimension ............................................................. 12-14

MAINTENANCE SECTION

Starter ................................................................. 15, 16

Disassembly I Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Test and Inspection Procedure ............................. ; ............... 18

Valve: Test and Inspection Procedure .................................... 19, 20

Disassembly I Assembly Instructions ....................................... 21

Annual PM Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

TROUBLESHOOTING

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25

INDEX .......................................................................... 26

3
 PLACING STARTER IN SERVICE
HOW TO ORDER A STARTER - - - - - - - - - -

(
ST400 IC 03 R 31 - 030
I :. _p~!QN
R - RIGHT HAND
CODE

ORIENTATION
ST400 - 44% ARC I - 1" NPT INLET L-LEFfHAND
(MAX. 150 PSI) Z - ZINC HOUSING
ST455 - 55% ARC NO LETTER - SAE 00 - CRADLE MOUNT
(MAX.) 120 PSI SPLIT FLANGE INLET 01 - SAE 1 FLANGE
ST499 - 99% ARC 03 - SAE 3 FLANGE
(MAX. 90 PSI)
C - GEAR RATIO

When ordering a Starter, refer to table below for correct pinion data.

PINION DATA

TEETH BLANK D.P. MOD. P.A. ROTATION PINION

10 10 8/10 20DEG RIGHT ST400-13-15
12 12 ST400-13-29
12 12
8/10 20DEG
20 DEG
RIGHT
ST400-13-31
(
6/8 RIGHT
12 12 6/8 20DEG LEFT ST400-13-32
9 9 3 15 DEG RIGHT ST400-13-77
11 11 3 15 DEG RIGHT ST400-13-85
11 12 8/10 20 DEG RIGHT SS350R-13-21
13 14 3.5 15 DEG RIGHT SS350R-13-895
24 12114 12 DEG LEFT SS175L-13-1448
10 11 10/12 20DEG RIGHT 04335055
9 10 3.5 15 DEG RIGHT 04595799
17 18 3.5 15 DEG RIGHT 04334371
11 3.5 20DEG RIGHT 04333969
13 13 3.5 15 DEG RIGHT 04332292
14 16 3.5 15 DEG RIGHT 04595807
14 3.5 14.5 DEG LEFT 04334363
12 4 14.5 DEG LEFT 04331724
14 15 3.5 20 DEG LEFT 04334389

For different models or special applications, contact your nearest Ingersoll-Rand

Distributor or Ingersoll-Rand, Engine Starting Systems, Box 8000, Southern Pines, NC 28387
(910) 692-8700 (

4
 HOW TO ORDER

STARTER ORIENTATION
INLET PORT

REF, HOLE OF
MOUNTING 0
FLANGE

' '

\
l~Xr~I
RIGHT HMll
( ROTATICX>t

SAE 0 I FLANGE

(Dwg. TPD1670-1)

For customer orientation of the starter: To purchase pre-oriented starter:

5. Loosen six Flange Cap Scre\vs.
6. Turn Flange to desired orientation. Note the
orientation n1arks on the exterior of the Housing.
Each mark 1neasures 30° of arch. There is a "O" 1nark
which aligns with the starter inlet.
7. Tighten the six Flange Cap Screws to 3-4 ft-lbs
(4--{i Nm) torque.
It is necessary to provide the orientation code \vhich is
the angle of the Mounting Flange relative to the starter
inlet port ("O" mark on the Housing). Therefore, the
orientation code 'viii be an angular n1easurement.
To obtain the orientation code, proceed as follo\vs:
I. Orient the starter so that the inlet port is pointed
straight up. The "O" mark on the Housing near the
Mounting Flange should be visible and pointed
straight up.
2. With the starter at this setting, position yourself so
that the Drive Pinion (2) is facing you.
3. Rotate the Mounting Flange clockwise until the
desired orientation is reached.
4. You \Vill derive the orientation code from a clock\visc
measurement of the angle from the "O" mark (inlet
port) to the reference hole of the Mounting Flange.
1lie Housing has indicator marks every 30°.
Example: ST400C03R3 l-060

5
 HOW TO ORDER
The following diagrams give dimensions and specifications for the components used when
installing a Model ST400 Engine Starting System
(
FILAMENT WOUND COMPOSITE AIR TANK (ST400)
ELLIPTICN_ 1£AOS
GAL. PART llJ A DIA. B LGTH, CQDR WT. """'15 C LGTH. 0 LGTH. E LGTH. F LGTH. 1.Vd.AXIS/IWl'.lR AXIS
45 AT45· 14NB 14,00 72.0 BLACK 39 61.34 14.00 7.00
45 A145·26 26.00 26.0 BLACK 40 I 13.7 6.0 7.1 12.0 26,00 13.0
53 AT53· 14NB 14.00 84,0 BLACK 43 73.34 14.00 7.00
60 AT60·26 26.00 31.0 BLACK 45 I 13.7 10.0 7.1 18.0 26.00 13.0
'NOTE FOR A TANK W/O BRACKET PLACE "NB" AT END OF PART NO.

SPECIFICATION NOTES:
1.VESSEL TO BE MANUFACTURED IN ACCORDANCE WITH SAE 1. HORIZONTAL TANKS CAN BE ROTATED 360 DEGREES WITH-
J10 LATEST REVISION. HOWEVER, TANK TO BE LEAK TESTED OUT AFFECTING PERFORMANCE OF INTERNAL DRAINING DE-
PER ASME SEC. 10 CODE: 1 1/2 TIMES RATED PRESSURE PNEU- VICE.
MATICALLY. 2. VERTICAL TANKS- PORT MUST BE DOWN.
2. MAX. WORKING PRESSURE 150 PSIG. 3. ALL FLANGE FITIINGS I NPT PORTS MOLDED AND WRAPPED
3. TEMPERATURE - MAX. 200 DEGREE FAHRENHEIT INTO TANK INSURING COMPLETE AND PERMANENT ENCAP-
MIN. -40 DEGREE FAHRENHEIT SULATION .
.,.
r·c·

(
1$1.o:ml"!
:~~-c C!Ot~S~~ l?1~f'°1 4·HO_.E5 FOR 3/B·lB E«-TS.
l,"100 nnEAD u:,;;JTH>.

1.,J-1~~,,.i,,.--~~
PEI.I U,._'U'~CflJ'IEI) SEU'
CLlfDllM) "Jl, VA>:ll•.JV
T<:il0<£ OOT Rll"'IN'3 320 !II LB5.

"'"

(Dwg. TPB979-1)

r
PIO'HR
CO\NECTQR
P/N 15300002

_ _."01"1AC~"J.!AG'l VA\ VFS

®
(J) PART NO. DESCR!PTIOll
@ ST400-A339 lELECTRO'llC VA'-Vt
a ST400·B339 ELECTRONIC V~-LVE
®
9
ST400·A339V fJANUi'.L VJ.LYE

(Dwg. TPD1796-1) (

6
 HOW TO ORDER
System Components

Flange Fittings

Ir•·•1
2.:ll

DIA. .408

01 -:-
.62 •:J/8-1&-UN-2B
4 HOLES
4 HOLES

t"NPTTHD.

FLANGE FLANGE KIT

ST400-18 ST400-K17
USED WITH KIT INCLUDES:
PART NO. DESffiJPTION CLOSED NIPPLE FLANGE, 0-RING (4)
51400-16 FLllNG€ KIT BOLTS & WASHERS

( (Dwg. TPD1660-1)

(-20-16) (-16)
REDUCER BUSHING FLANGE HEAD
ST400-81 ST400-19

_ ·
3/8-18 NPTF ~~,-~
I 1/2-14NPTF

@ ~- •
\T
l.:JJ
--r 1.:rn

PUSH BUTTON CONTROL VALVE

I 1 • _l
SWITCH SWIVEL FLANGE l.E 3/8-18 NPTF 3/8-18 NPTF
PART NO. OESCR I PT I ON
PART NO, DESCRIPTION SMB-618 90 DEGREE TANK FLANGE 2-WAY CHECK VALVE
ST400-A6!8 SWITCH SVB-G618 CHROfJE PLATE ST400-161 ST400-1052

(Dwg. TPD1664-1)
\j~~86~
~-,IT DRAIN VALVE
SOLENOID ACTUATED CONTROL VALVE ST400-1067
PART NO, VOLTAGE OE SCA I PT I ON
@ 1508!/P-10518 12 VDC LOOSE WIRES .76
!50B!J.P·AJ051C 12 VDC PIONEER CONNECTOR
P/N 15300002
l50B!JP·Z451B 24 VDC LOOSE WIRES

' J / 4 NPT
PRESSURE GAUGES .56
PART NO. OE SCA I PT I ON
@ I SOBf.~P- l 064 ISO psi DASH I.ANT.
15081.'P· 1064l 150 psi TEE ~~NT, NOTE: THIS DRAIN VALVE HAS AN 0-RING SEAL.
TIGHTENING BY HAND WITH A LARGE SCREW-
1/8-27 NPT~7/16-20 SAE 37' FLARE DRIVER WILL NORMALLY BE SUFFICIENT. EXCES-
CONNECTOR SIVE TIGHTENING MAY DAMAGE THE SEAL.
PART l'.'O. DESCRIPTION CLEARANCE NEEDED FOR PROPER OPERATION.
@ 51400-52 '-!ALE CC1"lNECTOA

(Dwg. TPD1662) (Dwg. TPA1594)

7
 HOW TO ORDER
System Components

3, 41 r=L:7t- I 5/rn-12
r' 5/Js-12
(

m
,50

I - 161 I - 161
STRAIGHT SPLIT FLANGE 22 1/2• SPLIT FLANGE !-161 '1-161
ST400-775 ST400-776 90• SPLIT flAOOE/37' FLARE SPLIT fl..\00£/37' FLARE

1
ST400-25
ST400·162

3.64 --i~ I 5/a-12

2 2-j-1
·" 5/a-12
.50

I -161
30" SPLIT FLANGE
ST400-846
1.12

1-161
45• SPLIT FLANGE 1-16 -201
Q8-~ 1-11 1/2 WT
ST400-777 45' SPLIT fLANGE/37' FLARE 1-16 -201
ST400-38 PIPE TO 37 • FLARE
ST~00-21
I 5/16· 12

2.38

l_ ,i::::::::::::i
,~,,~--'"'"
I - 161
{ - 16) 90" SPLIT FLANGE 1-161 1-20 -161
so· SPLIT FLANGE ST400-779 45' SPLIT fll.NG:E/37' FLARE 37' FLllRE SWIVEL
ST400-395 ST400-23 ST400-501

~2.99-j

I 5/16- 12
E118~
Li -11 1/2 NPT
(
I -161 ( - 161
37° SWIVEL FITTING
ST400-4 I l MALE PIPE FITTING
ST400-412

8
 PLACING SYSTEM IN SERVICE
- - - SYSTEM INSTALLATION - - -
AirTank
When connecting the starter to an air receiver tank
that is already in service, bleed off the air pressure in
the tank prior to installation.
Surface cleaning prior to painting may be
accomplished using any standard cleaning solvent, any
questions or deviations should be discussed with
Ingersoll-Rand.
Composite tank surfaces cannot exceed 200 degrees
farenheit for longer than ten (10) minutes. Paint booth
applications should be discussed witlt factory prior to
installation. · ·
Note: Because of heat transfer considerations between
the composite tank and the paint booth environment,
( 3mbient tempeatures can eXCeed the rated tentperature
of the tank for certain periods of time. Contact
Ingersoll-Rand prior to installation.
NOTICE
External Bracketing - Composite Tank
l. Select a bracket which provides stability and
structural integrity. The bracket should be selected for
the application based on environ1nental considerations
such as vibrational loading, additional \Vcighting, ease
of installation and ntaintcnance.
2. The bracket n1ust contain a neoprene barrier of at least
l/8" thickness between the metal strap and the
composite tank surface.
3 See page 10 for con1pression analysis to determine the
band strap fastening torque; the maxiinu1n allo\vable
external co1npressive pressure is 100 psi.
Wound-in Bracketing - Composite Tank
I. Use grade 8 bolt (or greater) for lower four bolts with
appropriate hardened plain washers. Apply grade 290
!octile or equivalent, and torque bolts to 45-50 ft-lbs.
2. Use grade 8 bolt (or greater) for upper four bolts with
appropriate hardened plain washers under bolt head.
Use a stover lock nut, and torque to 45- 50 ft-lbs.
Valve
I. Mount the ST400-A339 or ST400-B339 Electronic
Valve or ST400-A339M Manual Valve to the air
receiver as sho\vn in the installation diagrams. The
air flo\v arro\V 1nust point to\vard the starter.
2. Using the supplied flange fitting, tighten the four
flange bolts to 28-35 ft-lbs (38-47 Nm) torque.
3. For electrical installations, install the ST400-A6 I 8
Electrical Switch on the dash panel.See Dwg. TPB973
or Dwg. TPB975 for making wire connections.
For air installations, install the SMB-618 Starter
Control Valve on the dash panel. Connect the air lines
as shown in Dwg. TPB976.
4. Connect onc-8 air line from the ST400-1052 2-way
Check Valve to the ST400-A339 Relay Valve.
Mounting the Starter
I. To detennine the exact length of#l6 hose required,
run a piece of hose or some other flexible tubing of
the same_ dia1netcr from the valve on the air receiver
t~ the st~rter mounting location on the engine. After
determining the hose length required, attach 0-ring
sealed flange fittings as required.
2. ·Attach the hose to the outlet side of the valve with the
ST400-16 4 bolt split-flange provided. Tighten bolts
to 28-35 ft-lbs (38-47 Nm) torque.
3. At this point, detennine if it is ~onvenie;nt to attach
the hose to the starter b.efore actually mounting it on
the engine.
4. If possible, liberally grease the teeth of the ring gear
\Vith a good, sticky gear grease or 1notorcycle chain
lubricant. This will help to promote the life of the
starter pinion and engine ring gear.
5. Mount the starter in position and bolt it to the engine.
Refer to Dwg. TPB974.
System Actuation
Pressurize the co1nplete starting systc1n and using a soapy
solution, check the follo\ving locations in the live air line
for leaks:
• Valve/tank connection
• Fill-line to check valve on ST400 valve
• Air supply line to 2-way check valve

9
 PLACING SYSTEM IN SERVICE
Composite Tank Compression Analysis
for Band Straps (J-Brackets or C-Brackets)

GIVENS ... P: Maximum Compression Pressure (psi) = 100 psi

(
K: Lubrication Constant =
0.15 lubricated threads
0.20 dry threads (most common)
INPUTS ... D: Nominal Thread Pitch Diameter (inches)
R: Nominal Tank Radius (inches)
W: Minimum Strap Width (inches)
RESULTS ... F: Clamping Force (lbs)
T: Nut Torque (ft-lbs)
Step #I : F = (P)(R)(W) Given maximum compression pressure not exceed I 00 (psi),
calculate clamping force (pounds)
Step #2 : T = !KlCDl!Fl Use clamping force to calculate bolt torque (ft-lbs)
12
Example #1 Compression Pressure (psi) 100 Example #2 Compression Pressure (psi) 100
Tank Diameter (inch) 26 Tank Diameter (inch) 14
Band Width (inch) 4 Band Width (inch) 2.5
Tension Force (pounds) 5200 Tension Force (pounds) 1750
Lube Coef. 0.2 Lube Coef. 0.2
Bolt Thread Norn. Diameter (inch) 0.625 Bolt Thread Nom. Diameter (inch) 0.5
Fastener Torque 650 (inch-lbs) 54.17 (ft-lbs) Fastener Torque 175(inch-lbs) 14.58 (ft-lbs)
Result: For a 4" wide 26" diameter strap the torque on a 5/8" Result: For a 2.5" wide by 14" diameter strap the torque
threaded bolt should not exceed 54 ft-lbs. on a 112" threaded bolt should not exceed 14.5 ft-lbs.

(
ST400 Installation Diagram - Stationary Industrial

#4 HOSE I 1/4"1
*ST ARTER CONTROL VAL VE
ST900·267·16 STRAINER AIR PRESSURE GAGE---1 SMB-618 IBRASS/AIRI
* 150BMP· 1064L IAIR ONLYI
JIC 37° ADAPTOR 1/4" N.P.T.
* SS350·MC4
'4 HOSE I 1/4"1

HIGH PRESSURE
SUPPLY
I" HOSE

INLET FLANGE KIT

*ST400·Kl7 ~
RELAY VALVE I"
* SRV I00 OR ST 400 · A339M

'''
NOTE:
USE SEALANT
ON ALL PIPE
CONNECTIONS.
*SMB-441
*INGERSOLL·RAND PART NUMBER (Dwg. TPA1592-l)

10
 PLACING SYSTEM IN SERVICE

ST400 Installation Diagram - Electro - Mechanical

19 HOSE l l/2" I
• 12 VQ T POWER stf'f'L Y 2

lPIN HSPPS·J! DRY TN«

!AIR SUPPL YI

I PIN 6 --:::::..."'~IN~A'-=====~~~~~~==;~ 4

.,.'I'
W-- - --!#- .,.'I'
5 I
(

I DESCRIPTION
I STARTER

3 FITTING
4 FLANGE
5 H05£
7 0 I A?rflAGf.I VAL VE
9 SWITCt!

(Dwg. TPB973-1)

ST400 Installation Diagram - Manual

""'' oc
""''·
IP/N IGPPS·31

:I; :I:
*i·--*
·r ·1·
i i
•
I
DESCR I PT I ON
STARTER
2 TN.X
*-*
c1: c1:

J flTTlt-0
4
"-"""
5 HOSE
El DIAPl-AAGIJ VALVE
PUSH BUTT(t.I VALVE
ll SOLENO[O (Of'TION,O.U
GAGE
OO'*CTOA

(Dwg. TPB976)

11
 ST400 Starter Dimensions

STANDARD INDUSTRIAL
FITTING FITTING
2.000--j
['52.JJ I '·"'
[se.1]
2.293
[58.2]
3/IJ·l6 l.Nl>36 TYi'. f----f-+-- I .031 f--+-f--1.0JI
'.llll·16 ~C-36 TYi'. 1.030 .516 [20.2] .516 [26.2]
[w.2] [1J.1]
i:i1.000~11~ [13.1]
[2'5·"ll~
g!.659
2.062
['2.4] [10.?)
2.220 1 .o::rs 3·1"1.llCES
[56."J [w.4]
2.020~.0:JI
:SZ<i=1--+f~~

"
J_ [n .o] [:w.2]
NPTr~/

~r~~
'·"'
[1J.2] !•11 l/2
' + [se.o) RZ.S?S
[n.o]
. g!~:~ PILOT
g2,ol 01 ....

'-- - - ---,-- - - __J

g! .406 TYP.
[10.:J]
[Ill ,9J
::0
TYP. 111
120· ~
::0
['I _,_~, ""
~
2.057
J. 125
TYP, g!S.O:JO
[n.o] /) :J,G03----<
I //
' [93.0] [120]

"'
L -----------+--- ~
~:§
i:is.o::io
" //,71 ', [127.8]
'

== =
=

>
g!J.7SO

ri.2'56· [os.::i) .2so-H .wo Rl NG oc-R r/'a. Sl>t. 3 >t...ANG<. :<:

~5.002
[6.5]
,w. [s ...J I [6.eJ C)
(144.J] 2.reo 2.000 Cl)
[7~.Gl [.,.o.s) l.2""...0
o<S•
TYP. [Ji .a]
l'INION
'AA~
1------------12.178 1.740 j.?13.~90
[:J~.:J] [ ..... 2] PILOTJ.~9S
01 .... foo.i:il
LBO.O]
l-----------------1:'.l.010-----------------

-~
DUAL INCH
NOTES: DIMENSIONS (MM) [63.5]

1. WEIGHT 24 LBS (11.0 Kg)

2. FLANGE ROTATION INFINITE.
REF. MARKS EVERY 30 DEGREES.
Slit::. I FLANOE.

(Dwg. TPA1400i-1)

/~ ~
~
 ~

Electronic Valve ST400-B339

1/2-14 NPT

!REF! TORQUE BOLTS

12) I 28-34 FT. LBS.
[38-46 NMJ

PIONEER
P/N 15300002

11
~~r >
1
i----s. 74 I

[145.80] 12.0 LONG

~
:; ! .38 (304.Sl TYP
[34.92]
~

~
J/8-27 NPT
TANK PRESSURE

.---- tJ
]. 70
~
[;7o.s7~
[43.25]
:§
1/4-JB NPT
I
~
l .O" FLANGE 1.0" FLANGE TANK PRESSURE
STYLE STYLE 1/4-18 NPT
TANK PRESSURE l-----5.03_J
[127.84]

DUAL INCH
DIMENSIONS (MM)

SPECIFICATIONS
1. RATED OPERATING PRESSURE 150 PSIG.
2. RATED OPERATING VOLTAGE 12-24 VDC.
3. RATED CURRENT DRAW 750 mA.
(Dwg. TPA1398-1)
 Manual Valve ST400-A339M
1/2-14 NPT

1/8-27 NPT

G '
.
IREFI
TORQUE BOLTS
28·34 FT.LBS.
!21 1.38
[34.93]
lr3.07~ 1.96
lJ
l'Ti
ril
~
138-46 NMI
I [78~04] I
[49. 72]

.j>. 1.6~
A I I I ii ,

[42.14] 0

1.69 -
~
[42' 90]
TFANK

~-liill
lllU ...~
3 · 35
[85.05]
~
v
1/4-18 NPT
1/4· IB NPT
TANK PRESSURE
~
Cl)
1.0 .. FLANGE 1.0"" FLANGE TANK PRESSURE
STYLE STYLE

DUAL INCH
DIMENSIONS (MM)

SPECIFCATION
1. RATED OPERATING PRESSURE 150 PSIG. (Dwg. TPA1399-1}

,,---- ~ ~
 MAINTENANCE SECTION

(
...
~
.'ll
(/)

'"
.!:;
-e
iE!
g

-
i'.'!:
(/)

~
~

Ol

'
< Ol

\'
,\
\'
v'

15
 PART NUMBER FOR ORDERING t PART NUMBER FOR ORDERING t
I
2
I Drive Pinion Screw ............. .
Drive Pinion
SS350-394 7
8
Nameplate Tack ................ .
Return Spring .................. .
ST400-!00
ST400-700
for ST400CO!R15 ...... . ST400-13-15 9 Liner Assembly
for ST400C03R21 ...... . ST400-13-21 Standard Arc Right Hand .. ST400-A41R
for ST400C03R29 ...... . ST400-13-29 Standard Arc Left Hand .. . ST400-A41L
for ST400C03R31 ...... . ST400-13-31 55 % Arc Right Hand .... . ST455-A41R
for ST400C03R071 ..... . 04335055 55 % Arc Left Hand ..... . ST455-A41L .
for ST400C03R77 ...... . ST400-13-77 Full Arc Right Hand .... . ST499-A41R
for ST400C03R79 ...... . 04595799 Full Arc Left Hand ...... . ST499-A41L
for ST400C03R85 ...... . ST400-13-85 10 Housing Cover Gasket ........... . ST400-283
for ST400C03R91 ...... . 04595807 11 Housing Cover ................. . ST400-562
for ST400C03R95 ...... .
for ST400C03R832 ..... .
04334371
04333969
12
13
Housing Cover Bolts (4) ......... .
Housing
ST400-563
~
for ST400C03R893 ..... . 04332292 Aluminum ............ . ST400-40 ~
for ST400C03R895 ..... . SS350-13-895 Zinc ................. . 04595815 ~
~
for ST400C03L30 ...... . ST400-13-32 14 Vent Plug ..................... . ST400-546
-"' for ST400C03L32 ...... .
for ST400C03L92 ...... .
ST400-13-32
04334363
15
16
Front Drive Shaft Bearing ........ .
Drive Housing Seal ............. .
ST400-363
ST400-271 <::
for ST400C03L!Ol ..... . 04331724
ST400-13-32
17 Inlet Flange Assembly
(includes Flange (2), Flange
~
for ST400C03L895 ..... .
for ST400C03L942 ..... . 04334389 Mounting Bolts (4), Lock Washers (4)
and 0-ring) ...... , ............ . ST400-16 ~:::!
3 I for ST400C03L1448 .... .
Flange Cap Screws (6) ........... .
SS175L-13-1448
ST400-481 Starters with "!" in model number .. . ST400-Kl7
4 Flange Cover
for SAE 1 Flange ....... . ST400-480-01
~
for SAE 3 Flange ....... . ST400-480-03
for Cradle Mounting .... . 04332334
5 I Flange
SAE 1 Flange .......... . ST400-300-01
SAE 3 Flange .......... . ST400-300-03
6 I Nameplate .................... . ST400-301

~.
~
~
 MAINTENANCE SECTION
Al\vays \Vear eye protection \Vhen perforntlng any
maintenance on this starter.
Always turn off the air supply and disconnect the air
supply before installing, removing or adjusting any
accessory on this starter or before performing any
maintenance on this starter.
---~DISASSEMBLY-----
General Information
I. Do not disassemble the Starter any further than
necessary to replace worn parts.
2. When grasping a part in a vise, always use
leather-<:overed or copper-<:overed vise jaws to
protect the surface of the part and help prevent
distortion. This is particularly true of threaded
members.
( 3. Do not remove any part which is a press fit in or on a
subassembly unless the removal of that part is
necessary for replacement or repairs.
4. Always have a complete set of seals and 0-rings on
hand before starting any overhaul of a Model ST400
Starter. Never reuse old seals or gaskets.
5. When disassembling, always mark adjacent parts so
the n1embers can be located in the same relative
position when the starter is reassembled.
6. Never wash the Liner Assembly (8) in a solvent.
Disassembly of the Starter
I. Remove the Drive Pinion Screw (1) from the drive
shaft and remove the Drive Pinion (2).
2. Remove the six Flange Cap Screws (3) from the
Housing (13).
3. Remove the Flange Cover (4) and Flange (5)
simultaneously by pulling up on the Flange.
4. Remove the Front Drive Shaft Bearing ( 15) from the
Flange Cover.
5. Remove the Drive Housing Seal (16) from the Flange
Cover.
6. Turn the starter over and secure it vertically in a
fixture.
Use care \Vhen ren1oving the Housing Cover Bolts
(12) holding the Housing Cover (11) to the starter.
The Liner (9) is spring loaded and will protrude
approximately one inch beyond the Housing when
released.
17
7. To remove the Housing Cover (II), slowly loosen the
four Housing Cover Bolts (12) while holding the
Housing Cover (11) in place.
8. Slide the Liner Assembly (9) out of the Housing.
9. Remove the Return Spring (8)
-----ASSEMBLY-----
General Instructions
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 into a bearing recess.. .
3. Whenever grasping a starter or part in a vise, always
use leather-<:overed or copper-<:overed vise jaw8'
Take extra care with threaded parts or housings.
Assembly of the Starter
I. Place the Housing ( 13), front end down so that the
Return Spring (8) can be placed into the Housing.
2. Slide the Liner Assembly (9) into the Housing.
Orient the Liner so that the notch aligns correctly. with
the Housing inlet port and Liner air inlet port aligns
with the Housing air inlet port. Attach Housing
Cover Gasket ( 10) to Housing Cover.
3. Attach the Housing Cover (11) to the Housing with
just one Housing Cover Bolt (12). Engage only a few
threads so that the Housing Cover can be easily
rotated.
4. While pushing the Liner Assembly down against the
Return Spdng, rotate the Housing Cover over the
Liner to hold it down.
5. Tighten the Housing Cover Cap Screws to 5-6 ft-lb
(6.7-8 Nm) torque.
6. Press the Drive Housing Seal (16) into the Flange
Cover (4) with the sealing lip pointed down.
7. Press the Front Drive Shaft Bearing (15) into the
Flange Cover.
8. Fit the Flange (5) onto the Flange Cover so that the
counterbore of the Flange slides over the shoulder of
the Flange Cover conectly.
9. Carefully slide this assembly over the drive shaft.
Be careful not to tear the Seal lip. Orient the Flange
correctly.
10. Tighten the six Flange Cap Screws (3) to 3-4 ft-lb
(4-5.4 Nm) torque and apply Loctite.
11. Attach the Drive Pinion (2) to the drive shaft using
the Drive Pinion Cap Screw (I) and tighten to
53-58 ft-lb (72-79 Nm) torque and apply !octile.
 MAINTENANCE SECTION
TEST AND INSPECTION PROCEDURE
i{ WARNING.
When 90 psig air pressure is applied to the starter,
the Drive Pinion will be rotating at 2,800 rpm and
Drive Shaft and Drive Pinion will move forward
1.25". Keep face and hands away from rotating
Drive Pinion,
I. Orientation: Mounting Flange must be oriented per
the customer's order or engineering drawing. -If
orientation is not specifi~d by customer, standard
orientation will be supplied.
18
2. Free Speed (All Models): Install Starter on a test .(
fixture. Apply 90 psig to the starter motor. Minimum
free speed is 2,800 RPM.
3. Confirm Overrunning of Clutch: Turn the Drive
Pinion by hand in the direction of rotation. The
clutch should ratchet smoothly.
4. Confirm Drive Rotation: Turn the Drive Pinion by
hand in the direction opposite of rotation. The clutch
should not ratchet.
 MAINTENANCE SECTION

JNLY ON ST400-A339 ~

14 FOR ELECTRONIC:VALVE
ST400-A339 AND ST400-B339

( 10

FOR MANUAL
VALVE ANY FUTURE ORDERS OF ELECTRONIC
ST400-A339M VALVE LIMITED TO ST40!kB339 ONLY

-- FOR ELECTRONIC VALVE

ST400-A339, ST400-B339
&
8 MANUAL VALVE ST400-A339M

(Dwg. TPA1402---l)

19
 MAINTENANCE SECTION

PART NUMBER FOR ORDERING t

(
l Valve Housing ........................................................ . ST400-339
2 0-ring .............................................................. . Y325-010
3 Housing Cover
for Electronic Valve ............................................ . ST400-338
for Manual Valve .............................................. . ST400-338M
4 Valve Kit (includes 0-ring, Plunger and Pin Assembly, Grommet
Seal and Diaphragm Assembly) ........................................... . ST400-K619
5 .Cap .................................................... ··············· ST400-616A
6 Spring ........................ : ............................... , ...... . ST400-615A
7 Check Valve ........................................................... . ST400-l056
8 Plug (2) .............................................. , .............. . HSPPS-2
9 Cover Screws (6) ...................................................... . Y222-156-C
JO Plug (for Electronic Valve) ............. : ................................ . ST400-29
11 Solenoid Kit (for Electronic Valve) [includes Screw (2), Armature Assembly (1),
Wave Washer (1), Nut (I) and Face Plate (l)] ................................ . 119314
12 Coil (exhaust) (for Electronic Valve) ............................... , ....... . ST400-950E
13 Coil (pressure) (for Electronic Valve) ...................................... . ST400-950P
14 Set Screw (for.Electronic Valve) .......................................... . Y23-102
15 Flange Assembly (includes Inlet Flange (2 halves), Flange Mounting
Bolts (4), Lock Washers (4) and 0-ring) .................................... . ST400-16
16 Male Connector (2) ................................................... . ST400-52

(
TEST AND INSPECTION PROCEDURE

VALVE

Solenoids: Using a solenoid tester, apply 9 VDC minimum to 24 VDC maximum(+ or- .5 volts) to Solenoid.
The Solenoid should activate the Annature \Vith a 1ninirnum 9 volt charge and a "clicking" sound indicates that the Solenoid is
functioning properly. Follow this procedure for both the Exhaust Solenoid and the Pressure Solenoid.

20
 MAINTENANCE SECTION
AI,vays 'vcar eye protection 'vhcn perforn1ing any
maintenance on this valve.
Always turn off the air and electrical supply and
disconnect the air and electrical supply before
installing or removing any component on this valve,
.before making any adjustments on this valve or before
performing any maintenance on this valve.
----DISASSEMBLY-----
General Information
I. Do not disassemble the valve any further than
necessary to replace worn parts.
2. When grasping a part in a vise, always use
leather-covered or copper-covered vise jaws to
protect the surface of the part and help prevent
distortion. This is particularly true of threaded
members.
3. Do not remove any part which is a press fit in or on a
( subassembly unless the removal of that part is
necessary for replacement or repairs.
4. Always have a complete set of seals and 0-rings on
hand before starting any overhaul of the valve. Never
reuse old seals or gaskets.
Disassembly of the Valve
I. For Electronic Valve, remove the Retaining Nuts
(11) and Wave Washers (ll) from the Arnrntures (II).
Slide the Exhaust Coil (12) and Pressure Coil (13) off
of the Annatures.
2. Unscrew the Check Valve (7) from the Valve
Housing (I). Remove Plugs (8) from the Valve
Assembly.
3. For Electronic Valve, unscrew the Set Screw (14)
from the inside end of the Pressure Annature which is
in the Pressure Coil (13).
4. For the Electronic Valve, remove the Armatures by
unscrewing the two Screws (11) and lifting Face
Plate.
The Armature is lightly spring loaded.
5. Remove the six Cover Screws (9) from the Cover and
Valve Housing. Remove the Housing Cover (3) from
the Valve Assembly.
6. Remove the Diaphragm (4) from the Valve Housing
and the 0-ring (2) from the pocket in the Valve
Housing.
7. Unscrew the Cap (5) from the Valve Housing.
Remove the 0-ring (4) from the Cap. The Spring (6)
and Plunger should come out with the Cap. If not,
remove them from the Valve Housing.
8. Remove the Grommet (4) from the Valve Housing.
* Registered trademark of Mobil Oil Co.
21
-----ASSEMBLY------
General Instructions
1. Whenever grasping a valve or part in a vise, ahvays
use leather-covered or copper-covered vise ja\vs.
Take extra care with threaded parts or housings .
2. Apply a film of o--ring lubricant to all 0-rings before
final assembly.
Assembly of the Valve
I. Insert the rounded end of the Grommet (4) in the top
of the Valve Housing (I) through the valve body
hole. The top can be identified by the concentric
raised rings.
2. Lubricate the 0-rings on the Valve Stem (4) andc
Plunger (4) with Mobolith®* II. Push this assembly
through the Grommet from the bottom of the Valve so
that the Plunger seals on the valve seat.
3. Turn the Valve Housing over and place the Spring.(6)
on the Plunger with the s111aller diameter of the Spring
leading. ·
4. Place the large 0-ring (40) on the Cap (5). Guide the
Spring and Plunger into the Cap while screwing the
Cap into the Valve Housing. Tighten the Cap until it
seats snugly against the Valve Housing.
5. Place the 0-ring (2) into the pocket of the Valve
Housing.
6. Place the Diaphragm (4) on the Valve Housing,
making sure that the punched hole of the Diaphragm
is aligned over the 0-ring and that the plastic disk of
the Diaphragm is up.
7. Set the Housing Cover on the Valve Body so that the
0-ring shoulder fits into the diaphragm hole.
8. Attach the six Cover Screws (9) through the Cover
and Diaphragm and into the Housing. Alternately
tighten the Screws to 45-55 in - lb (5.1 - 6.2 Nm)
torque. Screw the Check Valve (7) into the Valve
Body to 40--50 ft/lbs (54-67Nm).
9. For Electronic Valve, attach the Armature Assembly
(11) to the Valve by placing the Plunger into the
annature case so that the rubber face is visible. Slide
the Armature Flange Plate (11) over the annature case
and attach this assembly to the Cover using the two
Screws (11). Tighten to 5-6 in-lb (.56-.67 Nm)
torque. Repeat this procedure for the other armature
assembly.
10. For Electronic Valve, screw the Plugs (8) into the
Valve Housing.
II. For the Electronic Valve, slide the Pressure Coil (13)
onto the Armature at the "P" marking on the Valve
Housing. Slide the Wave Washer onto the same
arn1ature. Screw on the Retaining Nut and tighten.
Repeat the above procedure to install the Exhaust
Coil (12) on armature at the "E" marking. Apply IR
#160 Grease to the exterior of the armature (II).
 ST400 PHOENIX SYSTEM
ANNUAL PM CHECKLIST
(

*VISUALLY INSPECT SYSTEM FOR DEFECTS

(i.e. TANK, HOSE, FLANGES). _ _

*VISUALLY INSPECT THE SOLENOID CONNECTIONS

ON THE ST400-B339. IF NECESSARY, CLEAN AND
RE-COAT WITH A CONDUCTIVE SEALANT TO PROMOTE
POSITIVE CONTACT. (COMPOUND RECOMMENDED IS A
TRUCK-LITE BRAND NYK-77). _ _

*REMOVE TWIST-OFF CAP ON THE ST400-B339 CONTROL

VALVE. IF NECESSARY, REPLACE WITH A VALVE TUNE-UP
KIT IR PART NUMBER ST400-K619 AND LUBE PLUNGER._ _

*TORQUE PINION CAP SCREW TO 53-58 ft-lb (72-79 Nm)- _ _

(

*TORQUE INLET FLANGE BOLTS TO 28-35 ft-lb (38-47 Nm) - _ _

NOTE: THE OPTIMAL PERIOD TO PERFORM A PHOENIX SYSTEM PREVENTATIVE

MAINTENANCE SCHEDULE IS IN THE FALL SEASON.

DATE COMPLETED: _ __
MECHANICS SIGNATURE: _ _ _ _ _ __

22
 Air Starter System Diagnosis
ST400 Phoenix Starter

IValve opens - Starter blow-by I

IStarter do!-s-n_o_t_e-ng_a_g_e...,]
t
Check drive pinion for damage. Make sure that the correct drive pinion is
on the starter. Replace drive pinion if necessary. Check for damaged flywheel.
Check for blockage in internal housing port of staher. Remove blockage. Check
main supply hose for blockage or hose flapper. Remove blockage or replace hose.
I

( t
Check system air pressure. Use truck tire gauge on
Schrader valve located on starter control valve.
-* I
ICranks
Should be 120 psi.
t.
,.-----t'-----,
I I
No, presssure is not 120 psi
~s, pressure is 120 PU
~c---~=:J
t. t t
Fill to 120 psi
JStill blow-byJ I I
Cranks

I
t I
t t
Cranks J Still blow-by J
LOO
t
loKl
Malfunctioning Valve - Drain air from reservior first by removing 1/4" plug on starte
valve opposite tank fill. Loosen cap on bottom of valve. Inspect plunger for damage
and/or proper lubrication. Lubricate or replace plunger if necessary. Measure
resistance of solenoid coils. Resistance should be approximately 30 ohms. Replace
solenoid coils if necessarv. •Refer to oaaes 19 - 21 for valve maintenance.

,.---t____,
I Go to next page I

23
 Air Starter System Diagnosis
ST400 Phoenix Starter

Icontinued from page 231

Starter blow-by

Valve checked

Remove starter - inspect ring gear for damage.

Roll engine to inspect ring gear teeth. Check
IValve operates properly I
starter pinion for damage.
i .
ICranks j
Replace damaged gear j No damage of ring
CoQ
t
_t____, gear or pinion

.----t
Re-install starter
Replace with new
starter
I
t
ICranks j

t
Co"K"J (

ILow Power - Cranks engine slo~

Follow instructions on Pages 23 &24

I Still cranks slow

--~-~
If extreme cold, check cold starting
aids for proper operation. (i.e.:
Ether System works, Block Heater
works)

24
 Air Starter System Diagnosis
ST400 Phoenix Starter

Starter will not stop operating or

Starter cuts out too soon

,-----,-*-......,...,..----.
Check system wiring
Refer to Pg. 11 Dwg. TPB973-1

Valve operates properly

( Malfunctioning Valve - Drain air from reservlor first by removing 1/4" plug on starter
valve opposite tank fill. Loosen cap on bottom of valve. Inspect plunger for damage
and/or proper lubrication. Lubricate or replace plunger If necessary. Measure
resistance of solenoid coils. Resistance should be approximately 30 ohms. Replace
solenoid coils if necessary.• Refer to pages 19 - 21 for valve maintenance.

Check system oil pressure

lockout switch (Terminal 150)
If malfunctioning: replace

25
 INDEX
Page

A
Assembly (
Starter ........................................................................... 17
Valve ............................................................................ 21

D
Dimensions
Starter ........................................................................... 12
Valve ......................................................................... 13, 14
Disassembly
Starter ........................................................................... 17
Valve ............................................................................ 21

Illustrations
Starter .... , ...................................................................... 15
System ....................................................................... 10, 11
System Components ........................................................... 6, 7, 8
Valve ............................................................................ 19

M
Model Coding ........................................................................... " 4
Mounting the Starter ............................................... ·" .................... 9 (

0
Orientation of the Starter ................................................................. 5

p
Parts Listing
Starter ........................................................................... 16
Valve ............................................................................ 20
Pinion Data .............................................................................. 4
Piping Diagrams ..................................................................... 10, 11

T
Testing
Starter ........................................................................... 18
Valve ............................................................................ 20
Troubleshooting
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 24, 25

26