Objective
Provide general diagnostic guidelines for air starters.
Procedure
Safety Warning:
- Read and understand all applicable manuals and safety regulations and guides before installing, removing operating, repairing, maintaining, changing accessories on, or working near this product.
- Always wear eye protection when operating or performing maintenance on a starter. The grade of protection required should be assessed for each use and may include impact-resistant glasses with side shields, goggles, or a full face shield over the glasses.
- Always turn off the air or gas supply and disconnect the air or gas supply hose before installing; removing or adjusting any accessory; or before performing maintenance on a starter.
Diagnostic guide below:
| Problem | Possible Cause | Solution |
| Motor will not run | No air supply | Check for blocked or damaged air supply lines or tank |
| Damaged Motor Assembly | Inspect motor assembly and power train; repair or replace as necessary | |
| Foreign material in Motor or piping | Remove Motor assembly and/or piping and check for blockage. Clean strainer. | |
| Blocked exhaust system | Remove Housing Exhaust Cover and check for blockage | |
| Defective Control Valve or Relay Valve | Replace Control Valve or Relay Valve | |
| Loss of power | Low air pressure to Starter | Check air pressure at inlet of starter |
| Restricted air supply | Check for blockage or damage to lines | |
| Relay Valve malfunction | Clean or replace lines or Relay Valve. Lube Relay Valve. | |
| Exhaust flow restricted | Check for blocked or damaged piping. Clean or replace piping. Check for dirt or foreign material and clean or remove. Check for ice build-up. Melt ice and reduce moisture build-up in Starter | |
| Damaged Motor components | Replace damaged parts | |
| For Models with Inertia Drive | ||
| Drive will not engage | Foreign material in starter drive | Remove obstruction |
| Damaged or worn drive parts | Check drive components and replace if necessary | |
| Motor turning in wrong rotation | Wrong combination of drive and motor components. Replace with correct rotation parts | |
| For Models with Pre-Engaged Drive | ||
| Drive will not engage | No pressure to drive housing port | Check air supply |
| Internal drive housing ports blocked | Remove blockage | |
| Fluid in drive components | Remove fluid | |
| Damaged or worn piston assembly, o-rings, or seals | Replace damaged or worn parts | |
| O-rings and seals dry | Re-lube o-rings and seals | |
| Defective Control Valve / solenoid valve | Replace Control Valve | |
| Motor runs and pinion engages, but does not rotate flywheel | Damaged or broken drivetrain | Disassemble drive train and replace worn or damaged parts |
| Motor turning in wrong rotation | Verify rotation direction. Possible wrong combination of drive and motor components. Replace with correct rotation parts. | |
| Excessive butt engagement | Damaged drive pinion or flywheel | Inspect drive pinion and flywheel and replace as necessary |
| Damaged starter drive or components | Inspect drive components and replace worn or damaged parts | |
| Low air pressure | Check air supply | |
| Wrong drive pinion | Replace with proper drive pinion | |
| Oil blowing out of exhaust | Oil in air supply line |
Inspect air line Turbine motors - remove source of oil including inline lubricators Vane motors - remove extraneous oil source, adjust inline lubricator. |
| Turbine motors - Worn or damaged rotor seals or static o-rings | Replace seals/rebuild motor as required | |
| Oil leaking from gear case; Air or gas leakage | Worn or damaged o-rings or seals | Replace as necessary |
| Loose joints | Assure joints fit properly and that starter assembly cap screws are properly tightened. Assure that all seals and o-rings fit and seal properly at their perimeters. Replace as necessary. | |
| Excessive high-speed operation | Operate according to recommendations | |
| High number of start cycles (wear out) | Replace worn components | |
| Pipe plug missing or leaking | Replace or reseal pipe plugs if leaking. | |
| Pressure Regulator or Relay Valve does not work | Failure of solenoid valve | Replace or repair solenoid valve |
| Inlet pilot port or Port on top of Valve clogged | Clear port | |
| Drive Piston or Pilot Piston leaks | Replace/rebuild as necessary | |
| Master Regulator Leaks | Knob on top overtight | Loosen and observe effect |
| Diaphragm and/or Piston damaged | rebuild or replace regulator as necessary | |
| Vent port dirty | clean, remove debris | |
Test and Inspection procedure
- Clutch Ratcheting: Turn the drive pinion by hand in the direction of starter rotation. The clutch should ratchet smoothly with a slight clicking action.
- Motor and Gearing Freeness: Turn the drive pinion opposite the direction of starter rotation. The pinion should turn by hand.
- Pinion Engagement: Apply 50 psig (3.4 bar) air pressure to the engagement "I" port while leaving the "O" port open. The drive pinion should move outward and air should escape from the "O" port. Repeat several times to ensure proper operation. Plug the "O" port and apply 150 psig (10.3 bar) to the "I" port. Assure no air or gas is escaping.
- Motor Action: Secure starter in a test fixture (flange mount) or vise and apply 90 psig (6.2 bar) using a 3/8" (9mm) supply line to the inlet of the motor. Starter should run smoothly and in the direction stamped on the nameplate. Chamfer on pinion teeth should be on the trailing edge of the gear tooth.
- Motor and Gear Case Seals: Plug the exhaust and slowly apply 20 psig (1.4 bar) to the inlet of the motor. Immerse the starter for 30 seconds in a nonflammable, bubble producing liquid. If the starter is properly sealed, no bubbles will appear.
Notes
Diagnostic guide based on ST150 Starter Maintenance Information Manual (47518999001)
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