Ingersoll Rand literature · Installation & maintenance manual
Ingersoll Rand SS815, SS825 and SS850 Series Starter Installation and Maintenance Manual (P6567)
The Ingersoll-Rand installation and maintenance manual for the Series SS815, SS825 and SS850 starters, which use an air-actuated piston to engage the drive pinion and are designed for gas operation on vehicular and stationary engines. It covers lubrication and lubricator installation, hose sizing, re-orientation and mounting, typical piping layouts including prelube and high-pressure systems, barring over the engine, full disassembly and assembly with torque values, a pinion engagement and motor test, troubleshooting, and separate parts lists for the SS815/SS825 and the SS850.
Document at a Glance
- Publisher
- Ingersoll Rand
- Document type
- Installation & maintenance manual
- Form / number
- Form P6567, No. 03531480, Edition 8, March 1995
- Language
- English
- Pages
- 24
- File
- PDF, 2.4 MB
What's in This Document
| Section | Pages | What it covers |
|---|---|---|
| Safety information and warning label identification | 1-2 | Warnings on pressure rating, gas operation, lubricants and venting the drive housing for natural gas use. |
| Placing starter in service: lubrication and installation | 3-4 | Lubricator selection, hose sizing and sealing, orientation of the housings, and mounting steps with control and relay valves. |
| Barring over the engine and installation of HDL2 lubricator | 5 | Using the starter to position the engine by hand, and mounting the HDL2 lubricator on the starter or remotely. |
| Mounting dimensions for Series SS815 and SS825 starters | 6 | Dimension drawing for the SS815 and SS825. |
| Piping diagrams | 7-9 | Typical vehicular, stationary, high-pressure and engine prelube installations. |
| How to order a starter: model coding | 9 | Model code chart (Dwg. TPD1495) for the three series; chart text is not machine-readable. |
| Parts list for SS815 and SS825 | 12-14 | Ordering numbers with rotation, ratio and pinion variants, accessories and the SS800-TK2 tune-up kit. |
| Parts list for SS850 | 16-17 | SS850 ordering numbers including its own kits and the SS850-TK2 tune-up kit. |
| Maintenance: lubrication and disassembly | 18-19 | Greases and oils used at overhaul, then teardown of the drive housing, motor and gear case. |
| Assembly | 19-22 | Rebuild of gear case, motor and drive housing with clearances and fastener torques. |
| Test and inspection procedure | 22 | Clutch ratcheting, freeness, pinion engagement and travel, vane action and seal checks. |
| Troubleshooting guide | 23 | Causes and fixes for no-run, power loss, slow or failed engagement, and a pinion that engages but does not turn. |
Key Specifications and Data
| Item | Value | Page |
|---|---|---|
| Lubricator for cranking cycles under 10 seconds | Ingersoll-Rand HDL2 with diesel fuel or 10W non-detergent motor oil; oil supply line pressure no more than 5 psi | 3 |
| Lubricator for cranking cycles over 10 seconds | In-line lubricator with 10W non-detergent oil, 1 to 3 drops per second | 3 |
| Supply line size | 1-1/2 in #24 hose or pipe up to 15 ft; 2 in over 15 ft | 3 |
| Control lines | 1/4 in #4 hose | 4 |
| Starter mounting bolt torque | 100 ft-lb (136 Nm) | 4 |
| Drive housing cap screw torque | 28 ft-lb (38 Nm) | 21 |
| Motor housing cover cap screw torque | 60 ft-lb (81.4 Nm) | 20 |
| Rotor pinion retaining screw torque | 90 ft-lb (122 Nm) | 20 |
| Drive gear screw torque | 57 ft-lb (77.3 Nm) | 21 |
| Drive pinion retaining screw torque | 80 ft-lb (108.5 Nm) for SS815 and SS825; 125 ft-lb (169.5 Nm) for SS850 | 22 |
| Drive gear grease | Approximately 8 oz (240 mL) of Ingersoll-Rand No. 130 Grease | 20 |
| Overhaul lubricant by temperature | SAE 10 non-detergent oil above 32°F (0°C); diesel fuel below | 18 |
| Pinion engagement test | 50 psig (3.4 bar / 345 kPa) to the IN port; 150 psig leak check with OUT port plugged | 22 |
| Motor vane action test | 90 psig (6.2 bar / 620 kPa) through a 3/8 in (9 mm) line | 22 |
| Motor seal test | 20 psig (1.4 bar / 138 kPa), exhaust plugged, immersed 30 seconds | 22 |
| Rear end plate to rotor clearance | .001 in (.02 mm) to .003 in (.07 mm) | 20 |
| Vane replacement limit | Width of 15/16 in (24 mm) or less at either end | 19 |
| Drive housing positions | 16 radial positions relative to the gear case; 3 positions on the bell housing; exhaust and inlet each 4 positions | 3 |
Drive pinion by starter model
| Starter model | Drive pinion |
|---|---|
| SS815GB03R31 | SS815R-13-31 |
| SS815GB03L32 | SS815L-13-32 |
| SS815GB03R91 | SS815R-13-91 |
| SS825GC03R91 | SS815R-13-91 |
| SS815GB03L92 | SS815L-13-92 |
| SS825GC03L92 | SS815L-13-92 |
| SS825GC03R25 | SS825R-13-25 |
| SS825GC03L26 | SS825L-13-26 |
| SS850GD09R51 | SS850R-13-51 |
| SS850FGD09R51 | SS850R-13-51 |
Pinion position check, pinion face to mounting flange face
| Series | Extended (150 psig on IN port) | Retracted |
|---|---|---|
| SS815, SS825 | 69.0 ± 2.0 mm | 45.0 ± 2.0 mm |
| SS850 | 222 ± 2.0 mm | 180 ± 2.0 mm |
Series-specific parts
| Part | SS815 | SS825 | SS850 |
|---|---|---|---|
| Rotor pinion | SS800B-17 | SS825C-17 | SS850D-17 |
| Drive gear | SS815B-9 | SS825C-9 | SS850D-9 |
| Tune-up kit | SS800-TK2 | SS800-TK2 | SS850-TK2 |
Models Covered
Model codes as printed in the document. Linked codes go to the matching Ingersoll Rand starter in our catalog.
SS815GB03R31 SS815GB03L32 SS815GB03R91 SS815GB03L92 SS825GC03R91 SS825GC03L92 SS825GC03R25 SS825GC03L26 SS850GD09R51 SS850GD09L52 SS850FGD09R51 SS850FGD09L52 SS815RB SS815LB SS825RC SS825LC SS850RD SS850LD
Service Kits and Part Numbers
| Part number | Description | Page |
|---|---|---|
| SS800-TK2 | Tune-up kit, SS815 and SS825 | 14 |
| SS850-TK2 | Tune-up kit, SS850 | 17 |
| SS800-K3 | Cylinder kit | 12 |
| SS850-K300 | Drive housing kit, SS850 | 17 |
| SS850-K150 | Bulkhead kit, SS850 | 17 |
| SS800R-K587 | Clutch jaw kit for SS815RB and SS825RC | 13 |
| SS800L-K587 | Clutch jaw kit for SS850LD | 17 |
| SS800-K703 | Piston kit, SS815 and SS825 | 13 |
| SS850-K703 | Piston kit, SS850 | 17 |
| SS800R-K8 | Drive shaft kit for SS815RB and SS825RC | 13 |
| SS850L-K8 | Drive shaft kit for SS850LD | 17 |
| SS800-K399 | Rear drive shaft bearing kit (bearing and retainer), SS815 and SS825 | 13 |
| SS850-K399 | Rear drive shaft bearing kit (bearing and retainer), SS850 | 17 |
| SS800-42A-5 | Vane packet (set of 5 vanes) | 12 |
| SS825-53 | Rotor | 12 |
| SS800B-17 | Rotor pinion for SS815 models | 12 |
| SS825C-17 | Rotor pinion for SS825 models | 12 |
| SS850D-17 | Rotor pinion for SS850 models | 16 |
| SS815B-9 | Drive gear for SS815 models | 14 |
| SS825C-9 | Drive gear for SS825 models | 14 |
| SS850D-9 | Drive gear for SS850 models | 17 |
| SS815R-13-31 | Drive pinion for SS815GB03R31 | 12 |
| SS815L-13-32 | Drive pinion for SS815GB03L32 | 12 |
| SS815R-13-91 | Drive pinion for SS815GB03R91 and SS825GC03R91 | 12 |
| SS815L-13-92 | Drive pinion for SS815GB03L92 and SS825GC03L92 | 12 |
| SS825R-13-25 | Drive pinion for SS825GC03R25 | 12 |
| SS825L-13-26 | Drive pinion for SS825GC03L26 | 12 |
| SS850R-13-51 | Drive pinion for SS850GD09R51 and SS850FGD09R51 | 16 |
| HDL2 | Lubricator | 14 |
| NL-24-8 | In-line lubricator | 14 |
Confirm part numbers against the serial and model plate of your starter. For any part not listed in our catalog, send us the number.
Barring over the engine with the starter (Overview)
- Disconnect the 1/4 in hose at the OUT port on the drive housing and plug that port.
- Remove the 3/8 in pipe plug from the center of the motor housing cover.
- Pressurize the IN port on the drive housing so the drive pinion engages the flywheel.
- Fit a 3/8 in square drive wrench through the cover into the square recess at the rear of the rotor.
- Turn the rotor by hand until the engine reaches the position you need.
An outline only. Follow the full procedure, torque values and safety warnings in the document (from page 5).
Test and inspection after assembly (Overview)
- Turn the drive pinion by hand in the rotation direction; the clutch should ratchet smoothly.
- Turn the pinion the opposite way; it should turn by hand, confirming motor and gearing freeness.
- Apply 50 psig to the IN port; the pinion should extend and air or gas should leave the OUT port.
- Plug the OUT port, apply 150 psig to the IN port, confirm no leakage and measure extended and retracted pinion positions.
- Supply 90 psig to the motor inlet through a 3/8 in line; the starter should run smoothly.
- Plug the exhaust, apply 20 psig to the motor inlet and immerse the starter in non-flammable solvent for 30 seconds; no bubbles should appear.
An outline only. Follow the full procedure, torque values and safety warnings in the document (from page 22).
Frequently Asked Questions
What is the drive pinion retaining screw torque on SS815, SS825 and SS850 starters?
The manual specifies 80 ft-lb (108.5 Nm) for SS815 and SS825 starters and 125 ft-lb (169.5 Nm) for the SS850.
Which tune-up kit fits the SS815, SS825 or SS850?
The SS815 and SS825 parts list gives SS800-TK2, and the SS850 parts list gives SS850-TK2.
Which models have a left-hand thread on the drive pinion retaining screw?
The manual states that models SS815RB, SS825RC and SS850RD use a left-hand thread, while SS815LB, SS825LC and SS850LD use a right-hand thread.
Do these starters need special venting when run on natural gas?
Yes. For natural gas operation the main exhaust must be piped away, and the drive housing vent is piped to a safe location through tubing that is not tied into other exhaust lines.
How can the starter be used to bar over the engine?
With the OUT port plugged and the IN port pressurized to engage the pinion, a 3/8 in square drive through the motor housing cover turns the rotor by hand to position the engine.
Need the parts or the starter in this document? Send the model number from your starter's plate and we will confirm the right Ingersoll Rand part or replacement.
Source: Ingersoll Rand, Form P6567, No. 03531480, Edition 8, March 1995. Summary and tables prepared by AirStartersDirect.com, an authorized Ingersoll Rand air starter distributor; the PDF is the authoritative version. Page numbers refer to the PDF file. Reviewed October 2026.
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