Ingersoll Rand literature · Installation & maintenance manual
Ingersoll Rand ST500 Series Air Starter Installation and Maintenance Manual (P7628)
Form P7628 is the Ingersoll Rand installation and maintenance manual for the ST500 Series (ST500F) turbine-powered air starter used to start reciprocating engines. It is aimed at installers and service technicians. It gives pinion data, model coding and orientation options, mounting dimensions, stationary and vehicular piping layouts, a full illustrated parts list with seal and tune-up kits, and step-by-step lubrication, overhaul and bench test procedures.
Document at a Glance
- Publisher
- Ingersoll Rand
- Document type
- Installation & maintenance manual
- Form / number
- Form P7628, No. 04579546, Edition 5, January 2011
- Language
- English
- Pages
- 16
- File
- PDF, 2.1 MB
What's in This Document
| Section | Pages | What it covers |
|---|---|---|
| Product Safety Information | 2 | States the intended use of the starter and points to the separate air starter safety manual, form 45558624. |
| Lubrication and Specifications (Pinion Data) | 2 | Names the gear oil and grease used and tabulates the available pinions by code, tooth count, pitch, diameters and rotation. |
| Model Coding | 3 | Diagram of the model code positions, flange choices and the exhaust, drive housing and flange orientation options. |
| Mounting Dimensions | 4 | Dimension drawing with inlet, outlet and control port thread sizes and pinion travel. |
| Installation (Typical Stationary and Vehicular) | 5-6 | Piping diagrams for stationary air or gas installations and vehicular installations with Ingersoll Rand part numbers. |
| Cross Section, Exploded View and Part List | 7-10 | Drawings and the item-numbered parts list, including motor, gearing, drive assembly, kits and accessories. |
| Placing the Starter in Service | 11-12 | General installation guidance, strainers, re-orienting the housings and the step-by-step mounting and control hook-up. |
| Maintenance: Lubrication and Disassembly | 12-13 | Oil and grease quantities and the teardown order for the pinion, flange, motor, gear cases and drive housing. |
| Cleaning and Inspection of Parts | 13 | How to clean the starter drive and sealed bearings and which seals and bearings to discard. |
| Assembly | 13-14 | Reassembly of the drive gear, gear case, piston, drive housing, intermediate gear case, motor housing, flange and pinion with torque values. |
| Test and Inspection Procedure | 15 | Bench checks for clutch ratcheting, freeness, motor action, pinion engagement and seal integrity. |
| Parts and Maintenance | 15 | Notice on genuine replacement parts, authorized repair and recycling at end of life. |
Key Specifications and Data
| Item | Value | Page |
|---|---|---|
| Application | Starting reciprocating internal combustion engines, operated remotely | 2 |
| Flange options | SAE 01, SAE 03, Mitsubishi (codes 24 and 26) | 3 |
| Inlet / exhaust outlet | 1 1/4-11 1/2 NPT inlet; 2-11 1/2 NPT outlet | 4 |
| Control and metering ports | 1/4-18 NPT | 4 |
| Pinion travel | 1.000 in (25.40 mm) | 4 |
| Supply line size | 1-1/4 in hose or pipe up to 15 ft (4.6 m); 1-1/2 in beyond 15 ft | 11 |
| Inlet strainer | 300 mesh (50 micron filtration), required in each starter inlet line | 11 |
| Orientation positions | Drive housing 18 positions; exhaust port 4; air inlet 4 | 11 |
| Intermediate gear case oil | 55 ml (1.9 fl oz) 80W90 gear oil | 12 |
| Rear motor bearing oil | 7 ml (0.24 fl oz) 80W90 hypoid gear oil | 12 |
| Offset gear case grease | Approx. 0.24 kg (8 oz) Ingersoll Rand No. 130 grease | 12 |
| Mounting bolt torque | 100 ft-lb (136 Nm) | 12 |
| Motor housing / inlet cover cap screw torque | 25 ft-lb (34 Nm) | 14 |
| Drive housing cap screw torque | 100 in-lb | 14 |
| Flange cap screw torque | 12-14 ft-lb (16.3-19.0 Nm) | 14 |
| Pinion cap screw torque | 53-57 ft-lb (72.1-77.5 Nm) | 14 |
| Drain and filler plug torque | 5-10 ft-lb (6.8-13.6 Nm) | 14 |
| Bench test pressures | Motor run 90 psig (6.2 bar); pinion engagement 50 psig (3.4 bar); engagement leak check 150 psig (10.3 bar) | 15 |
| Relief valve setting (stationary piping) | 15 psi above regulator setting | 5 |
| Operating medium | Air or gas; main exhaust must be piped away for natural gas operation | 5 |
ST500 pinion data (Edition 5)
| Pinion code | Teeth | Blank | DP/MOD | PD (in) | PD (mm) | PA | Rotation | OD (in) | OD (mm) |
|---|---|---|---|---|---|---|---|---|---|
| 25 | 11 | 12 | 6/8 | 1.833 | 46.56 | 20° | Right | 2.250 | 57.15 |
| 29 | 12 | 12 | 8/10 | 1.500 | 38.10 | 20° | Right | 1.825 | 46.36 |
| 85 | 11 | - | 8.47 | 1.299 | 32.99 | 15° | Right | 1.600 | 40.64 |
| 893 | 13 | - | 3.50 | 1.791 | 45.50 | 15 | Right | 2.067 | 52.50 |
| 31 | 12 | 12 | 6/8 | 2.000 | 50.80 | 20 | Right | 2.250 | 57.15 |
| 77 | 9 | - | 3.00 | 1.063 | 27.00 | 15 | Right | 1.390 | 35.31 |
| 32 | 12 | 12 | 6/8 | 2.000 | 50.80 | 20 | Left | 2.250 | 57.15 |
Models Covered
Model codes as printed in the document. Linked codes go to the matching Ingersoll Rand starter in our catalog.
ST500F
Service Kits and Part Numbers
| Part number | Description | Page |
|---|---|---|
| ST500-SK1 | Seal kit (all parts marked *) | 10 |
| ST500-TK1 | Tune up kit (all parts marked **) | 10 |
| ST500L-K108D | Drive shaft kit, left hand | 10 |
| ST500R-K108D | Drive shaft kit, right hand | 10 |
| ST500-K166 | Flange kit, 1-1/4 in pipe (inlet flange kit) | 10 |
| ST500R-APDR | Drive assembly, right hand | 9 |
| ST500L-APDR | Drive assembly, left hand | 9 |
| 150TMFR-A53 | Motor assembly, 150TMP, RH | 9 |
| 150TMFL-A53 | Motor assembly, 150TMP, LH | 9 |
| 150TLFR-A53 | Motor assembly, 150TLP, RH | 9 |
| 150TLFL-A53 | Motor assembly, 150TLP, LH | 9 |
| 150TMF-A37 | Gearcase assembly (intermediate) | 9 |
| 150TMF-A108B | Gearhead assembly | 9 |
| ST500-40 | Motor housing | 9 |
| ST500-300 | Drive housing | 9 |
| ST500-704 | Piston | 9 |
| ST500-301-01 | Flange, SAE 01 | 9 |
| ST500-301-03 | Flange, SAE 03 | 9 |
| ST500-674 | Muffler | 10 |
| ST500-A735 | Exhaust deflector assembly | 10 |
| ST500-K740 | Exhaust tube kit | 10 |
| SMB-618 | Starter control valve (brass, air) | 5 |
| SMBG-618 | Starter control valve (chrome, gas) | 5 |
| SRV125 | Starter relay valve, 1-1/4 in | 11 |
| 150BMP-1051B | Solenoid valve, 12 V | 10 |
| 150BMP-2451B | Solenoid valve, 24 V | 10 |
| 150BMP-1064L | Air pressure gauge (air only) | 6 |
| ST900-267-24 | 300 mesh strainer for 1-1/2 in lines | 11 |
| ST900-267-32 | 300 mesh strainer for 2 in lines | 11 |
| ST900-267-48 | 300 mesh strainer for 3 in lines | 11 |
Confirm part numbers against the serial and model plate of your starter. For any part not listed in our catalog, send us the number.
Mounting the starter (Overview)
- Use a receiver tank rated at least to the starter's maximum operating pressure; bleed and drain an in-service tank first.
- Fit the SRV125 relay valve to the tank with a 1-1/4 in short nipple, using the port marked IN.
- Mount the SMB-618 control valve (or the 12 V solenoid valve) and the pressure gauge, and connect them to the relay valve with 1/4 in hose.
- Run 1-1/4 in hose from the relay valve outlet to the starter, greasing the ring gear teeth if possible.
- Mount the starter on the flywheel housing and torque the bolts to 100 ft-lb (136 Nm).
- Connect the control valve DEL port to the drive housing IN port, and the drive housing OUT port to the relay valve.
- Pressurize the system and soap-test every connection; there must be no leaks.
An outline only. Follow the full procedure, torque values and safety warnings in the document (from page 11).
Bench test after overhaul (Overview)
- Turn the pinion by hand in the starter direction; the clutch should ratchet smoothly.
- Turn the pinion the opposite way; it should turn freely by hand.
- Run the motor on 90 psig (6.2 bar) through a 3/8 in line and confirm smooth running in the nameplate direction.
- Apply 50 psig (3.4 bar) to the IN port and confirm the pinion moves out and air leaves the OUT port; then plug OUT and hold 150 psig (10.3 bar) with no leaks.
- Plug the exhaust, pressurize the motor inlet and immerse the starter for 30 seconds in a nonflammable bubble liquid to check the seals.
An outline only. Follow the full procedure, torque values and safety warnings in the document (from page 15).
Frequently Asked Questions
What oil goes in an ST500 air starter?
The intermediate gear case takes 55 ml (1.9 fl oz) of 80W90 gear oil and the rear motor bearing reservoir takes 7 ml (0.24 fl oz) of 80W90 hypoid gear oil; the manual warns not to overfill either.
What is the ST500 pinion cap screw torque?
The pinion cap screw is torqued to 53-57 ft-lb (72.1-77.5 Nm). It loosens clockwise on right-hand models and counterclockwise on left-hand models.
Can the ST500 starter run on natural gas?
Yes, the stationary piping diagram covers air or gas; for natural gas the main exhaust and drive housing vent must be piped to a safe location, and a chrome gas control valve (SMBG-618) is listed.
Which seal and tune-up kits fit the ST500?
The parts list names ST500-SK1 as the seal kit and ST500-TK1 as the tune up kit, with drive shaft kits ST500L-K108D and ST500R-K108D.
What size supply hose does an ST500 starter need?
Use 1-1/4 inch hose or pipe for supply lines up to 15 feet (4.6 m) and 1-1/2 inch for longer runs, keeping tees and elbows to a minimum.
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 P7628, No. 04579546, Edition 5, January 2011. 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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