48417802Edition 1

August 2012

Save These Instructions

Air Starters for Internal Combustion EngineSS100 series

Product Information

Product Safety Information

Intended Use: The SS100 series air starters are intended for use in starting reciprocating internal combustion engines. These starters are designed to be operated from a remote location after proper installation on the engine requiring starting.

Related DocumentsSafety Information Manual – 45558624Maintenance Information Manual – 48393383Parts Information Manual – 48393391

Manuals can be downloaded from www.ingersollrandproducts.com

Safety Symbol Identification

CLOSED

Read all manuals supplied with the starter before installing, operating, or

servicing.

Turn off air or natural gas supply before installing or

servicing the starter.

When using natural gas, all exhaust must be piped away

to a safe location where there is no risk of ignition.

When using natural gas, all exhaust must be piped away

to a safe location where there is no risk of inhalation.

Operating Guidelines

WARNING

• Never exceed the nameplate max. operating pressure rating. • If operating at 150 psig (10.34 barg), fitting 48393474 must be used at the inlet. • Always release the start button immediately after the engine starts. • Liberally grease the teeth on the pinion and ring gear with a quality heavy duty open gear lubricant. This will help

promote the life of the ring gear and the drive pinion. • For natural gas operation, starter main exhaust must be piped away. To pipe the intermediate housing vent, remove the

intermediate housing vent and replace it with a suitable tubing line. The tubing must vent at a safe location and must not be interconnected with any other exhaust lines which might introduce a back pressure on the intermediate housing.

General Information • The SS100 series air starter can be configured to operate as a pre-engaged starter similar to the SS175 series air starter or

as an inertia type starter similar to the 3BM and 5BM series air starters. Study the Piping Diagram sections of this manual. It is recommended that the starter be connected as shown.

• 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 in the exhaust port will restrict the flow through the motor. The number of tees and elbows, and the length of the supply line should be kept to a minimum.

• On all vehicular installations and on stationary engines subject to vibration, use flexible hoses instead of rigid pipe connections. Vehicle and engine vibration will loosen rigid pipe connections, whereas hoses will absorb the vibration and connections will remain tight.

• Supply lines must be free of contaminants. New piping must be free of scale and welding slag. • All connections must be air tight. Use Ingersoll Rand SMB-441 Sealant on all NPT connections throughout the system. • Take caution to not damage threads. Damaged threads can cause starter to be inoperable. • 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 and could cause corrosion in the starter motor or, worse yet, freeze solid in cold weather so that the Starter would be inoperative.

• Installation of a “glad hand” is recommended for emergency re-pressurizing of the system. To keep the “glad hand” clean and free of dirt, and to protect it from distortion, a second “glad hand” closed by a pipe plug can be mated to it, or a glad hand protector bracket can be used.

Orientation of the Starter • If the factory orientation will not fit your engine, the starter orientation may be changed by re orienting the flange or the

motor housing. Attempt to fit the engine by re orienting the flange first.2 48417802_ed1

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Flange Orientation • Loosen the 8 screws clamping the flange to the drive housing and rotate the flange to the desired position. It may be

advantageous to loosen the screws, place the starter on the engine, then rotate to the desired position. The orientation may be marked then the starter removed and the flange tightened. Tighten screws to 9.0-10.2 Nm [80-90 in-lb].

Motor Housing Orientation • Reference the starter model code located on the rear of the starter and the Inlet/Exhaust Orientation section of this

manual to determine the current orientation and which orientation is desired. The motor housing can be re oriented without removing the motor if switching between orientations 23, 30, or 01 or if switching between orientations 21, 10, or 03. See Procedure A. The motor must be removed if switching between those two orientation groups. See Procedure B.Example: - If changing from a 23 orientation to a 30 orientation, the motor can remain in the motor housing. See Procedure A. - If changing from a 23 orientation to a 21 orientation, the motor must be removed from the motor housing. See Proce-dure B.

Procedure A:1. Determine desired orientation.2. Place starter with pinion up and remove intermediate housing by loosening (4) screws securing it to the motor housing.3. Ensure motor housing O-ring is in place and re-assemble intermediate housing assembly to motor housing in the

desired orientation. Tighten (4) screws in a cross pattern to 5-7 Nm [44-62 in-lb].

Procedure B:1. Remove motor cover, O-ring, intermediate housing, and motor housing O-rings from motor housing.2. Place motor housing assembly with pinion up and lift motor housing from motor. Note orientation of motor housing

exhaust.3. Flip motor housing so that the exhaust is on the opposite side as before.4. Place motor housing over motor ensuring motor dowel is located on the inlet side of motor housing and properly

aligned. See Dwg. 48402598 SH4.5. Place motor housing O-ring on motor housing.6. Apply light coat of O-ring lubricant to pinion shaft seal in intermediate housing.7. Install intermediate housing assembly to motor housing in the desired orientation. Tighten (4) screws in a cross pattern

to 5-7 Nm [44-62 in-lb].8. Place starter with pinion down.9. Place motor housing O-ring on motor housing.10. Ensure motor is fully seated against intermediate housing by pressing the motor by hand.11. Install motor cover with O-ring. Incrementally tighten screws in a cross pattern until cover is fully seated. Tighten

fasteners to 5-7 Nm [44-62 in-lb].

Align motor dowel with hole Flipped motor

housing orientation

(Dwg. 48402598 SH4)

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Engine BarringOccasionally it may be desirable to bar over the engine in such a manner that any given piston can be stopped at any location. The SS100 series of starters has the ability to perform this function.

WARNING

1. Turn off the air or natural gas supply to the starter before attempting to use the starter to bar over the engine.2. Isolate th e starter engagement circuit by removing the engagement hoses. Cap any open hoses.3. Plug both “out” ports in the intermediate housing.4. Plug one “in” port in the intermediate housing.5. Engage the pinion with the ring gear by applying regulated air at 30-90 psig to the single open “in” port in the intermedi-

ate housing. See Dwg. 48402598 SH6.6. Remove the 3/8 NPT plug from the motor cover.7. Insert an 8mm hex key through the motor cover to engage the hex recess in the rotor.8. Manually rotate the rotor until the engine is cranked to its desired position.

In port.Apply 30 - 90 PSIG to engage pinion.Plug opposite side.

Remove plug

Out port.Plug both sides.

(Dwg. 48402598 SH6)

Mounting DimensionsDimension (All Ref)

Flange A B C Ref SAE J542SS100-301-01 206.73 46.9 50.8SS100-301-03 206.73 46.9 50.8SS100-301-04 219.43 34.2 38.1

2X 1∕8 - 27NPT

20.00

(3.94) (B)

(C)

(12.70)

(18.00)

(35.24)

Exhaust1½ - 11½ NPT

2X Inlet1 - 11½ NPT

2X out port1∕8 - 27 NPT

2X in port1∕8 - 27 NPT

(103

.75)

(101

.00) (1

97.8

7)

(221

.40)

(74.12)

(132.83)

(180.75)

(A)

(271.87)

(171.12)

19.50pinion travel

(Dwg. 48402598 SH1)

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Piping Diagram - Pre-engaged

See Note 1

8

9

11

See Note 13

2

1

StationaryApplication

Vehicular Application5

4

Optional

Flow Direction

10

7

6

(Dwg. 48402580)Note: 1. For natural gas operation, piped exhaust must be used and intermediate housing vent plug removed. All exhaust and

intermediate housing must be vented to a safe location.

Item Description Item Description1 Pressure Regulator 7 Push Button or Solenoid2 Air Strainer 8 Pressure Gauge3 Relief Valve

91 inch Hose (under 30 feet)

4 Tank 1-1/4 inch Hose (over 30 feet)5 Check Valve 10 1/4 inch Hose6 Starter Relay Valve 11 Splash guard or Muffler

Piping Diagram - Inertia

See Note 18

9

11

10

See Note 1

See Note 2

3

2

1

StationaryApplication

Vehicular Application5

4

Optional

Flow Direction

Detail - A Scale 1:1

Detail - A

7

6

(Dwg. 48407167)Note: 1. For natural gas operation, piped exhaust must be used and intermediate housing vent plug removed. All exhaust and

intermediate housing must be vented to a safe location.2. Connect inlet port to “I“ port with minimum length of tubing for inertia operation. See mounting dimensions illustration

for port detail.

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Item Description Item Description1 Pressure Regulator 7 Push Button or Solenoid2 Air Strainer 8 Pressure Gauge3 Relief Valve

91 inch Hose (under 30 feet)

4 Tank 1-1/4 inch Hose (over 30 feet)5 Check Valve 10 1/4 inch Hose6 Starter Relay Valve 11 Splash guard or Muffler

Model CodeSS100P R -

Flange code

Pinion code

Inlet orientation

Exhaust orientation

Flange codes:01 – SAE 0103 – SAE 0304 – SAE 04GM – GM

Pinion codes:See Pinion Table

Inlet/Exhaust orientation:See Inlet/Exhaust Orientation section.

Inlet/Exhaust Orientation

3

2

1

0

23 30 01

031021

(Dwg. 48402598 SH3)

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Flange Selection*Reference SAE J542

SAE 01 *SAE 03 *

GM SAE 04 *

3X ø (10.80) 3X ø (16.74)2X (90)

2X (120)

ø (88.80)pilot dia

2X ø (11.98)

ø (82.47)pilot dia

ø (92.00)pilot dia

(Dwg. 48402598 SH5)

Pinion Selection TableTeeth Diametral Pitch /

ModulePressure Angle Outer

Diameter (mm)Pitch

Diameter (mm)

Pinion Code

Part Number

8 8/10 20° 33.02 25.40 092 SS100-13-0929 8/10 20° 36.83 28.58 09 SS100-13-099 3 MOD 14.5° 34.80 27.00 77 SS100-13-77

10 10/12 20° 32.17 25.40 071 SS100-13-07110 8/10 20° 40.01 30.48 15 SS100-13-1510 8/10 20° 36.83 31.75 13 SS100-13-1310 6/8 20° 48.69 42.34 17 SS100-13-1710 8 20° 40.45 31.75 132 SS100-13-13210 2.5 MOD 14.5° 33.00 25.00 71 SS100-13-7110 3 MOD 14.5° 37.80 30.00 81 SS100-13-8111 8/10 20° 40.01 34.93 19 SS100-13-1911 8/10 20° 43.18 34.93 21 SS100-13-2111 6/8 20° 57.15 46.57 25 SS100-13-2511 2.5 MOD 14.5° 35.80 27.50 73 SS100-13-7311 3 MOD 14.5° 40.80 33.00 85 SS100-13-8512 10/12 20° 37.34 30.48 073 SS100-13-07312 8/10 20° 46.36 38.10 29 SS100-13-2912 6/8 20° 57.15 50.80 31 SS100-13-3113 8/10 20° 49.53 41.28 37 SS100-13-3715 3 MOD 14.5° 52.80 45.00 99 SS100-13-99

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PerformancePressure

psig (barg) Breakaway Torque

lb-ft (Nm)Speed @

Max power RPM Max Power

hp (kW)Flow@

Max power SCFM (L/s)

30 (2.07) 16 (22) 1290 2.3 (1.7) 110 (52)

60 (4.14) 39 (53) 1625 6.4 (4.8) 215 (101)

90 (6.20) 55 (75) 1800 9.6 (7.2) 315 (149)

120 (8.30) 75 (102) 1900 13.8 (10.3) 415 (196)

150 (10.34) 75 (102) 1900 13.8 (10.3) 415 (196)

TroubleshootingTrouble Probable Cause Solution

Motor will not rotate. No air supply. Check for blockage or damage to air or natural gas supply lines or tank.

Obstructed inlet, exhaust, or control circuits. Check for blockage. Remove blockage or replace blocked parts.

Seized motor. Add 2cc IR #10 oil to motor. Damaged motor parts. Disassemble motor and replace broken parts. Defective control valve or relay valve. Replace control valve or relay valve.

Loss of power. Obstructed inlet, exhaust, or control circuits. Check for blockage. Remove blockage or replace blocked parts.

Malfunctioning control valve or relay valve. Clean or replace control lines. Replace control valve or relay valve.

Damaged or worn motor assembly. Disassemble motor and replace damaged or worn parts.

Damaged or worn drive parts. Disassemble drive housing and replace broken parts.

Starter drive does not engage ring gear or engages and disengages ring gear very slowly.

Damaged drive parts. Disassemble drive housing and replace broken parts.

Malfunctioning control valve or relay valve. Clean or replace control lines. Replace control valve or relay valve.

Clogged control circuit. Clean or replace control lines. Replace control valve or relay valve.

Motor runs and pinion engages, but does not rotate.

Broken gearing or clutch. Disassemble drive housing and replace broken parts.

Parts and MaintenanceWhen the life of the tool has expired, it is recommended that the tool be disassembled, degreased and parts be separated by material so that they can be recycled.

Tool repair and maintenance should only be carried out by an authorized Service Center.

Refer all communications to the nearest Ingersoll Rand Office or Distributor.

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