Contents

Getting Started 2
The Startwell Starter 3
Your Starter Type 4
Installation 4
Operation 6
Unwinding 6
Slow Engine Cranking 6
Dual Starting Engines 6
Cold Starting 7
Trouble Shooting 7
Position Code Procedure 8

Appendix I Starter Sizes 10

Appendix II Specifications 10
Appendix III Parts & Tool List 11
Appendix IV Important Operating
Instructions 13
Appendix V Anticlockwise Starter
Operation 14
Appendix VI Routine Testing of
Startwell Starter 15
Startwell Getting Started

Getting Started

Thank you for purchasing the Startwell Mechanical Starter.

The starter should provide you with thousands of maintenance free engine starts. If for any
reason you do experience any problems with your starter please write, or telephone us
directly, contact your local agent who will be happy to resolve your problem or visit our
website for more information at www.startwell.com.

This booklet provides you with all the information you should need to install and operate your
Startwell Starter.

Contents of Box

• Starter
• Winding Handle,
• Getting Started Operator’s Handbook,
• Operating Instruction Stickers, as required
• Check Card
• Bolts/Nuts/Spacer, as required

Contact information:

Startwell Engineering UK Limited

5 Crystal Centre, Crystal Way,
Elmgrove Road, Harrow,
Middlesex, HA1 2HP
United Kingdom.

Tel: +44 (0)20 8863 4450

Fax: +44 (0)20 8863 4410
Email: [email protected]

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 The Startwell Starter

1 Front Housing 5 Reset Knob 9 Drive Gear 13 Circlip

2 Viewing Window 6 Input Adaptor 10 Spacer Shims 14 Drive Ratchet
3 Body 7 Rear Housing 11 Drive Shaft 15 Lock
4 Trip Lever 8 Bevel Pinion 12 Drive Nut 16 Drive Pinion

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Startwell Getting Started
Startwell Getting Started

Your Starter Type

You can check the starter type from the name plate situated at the top of your Startwell
Starter.

Part Number (PN.)

This code identifies the
starter range, direction
of rotation and finish.

Serial Number (SN.)

This is a unique number
identifying your starter.

Installation
CAUTION: Do not attempt to wind and trip the starter unless it is
fitted on an engine. The unit will break if it is held in a vice
energised and released. The warranty will NOT BE VALID

The Startwell Starter is easy to install and operate. It requires no special skills or tools. You
should, however, still read the following step-by-step instructions before fitting or operating
the starter.

Rotation:
a) The SNC, SDC, SDCH, SXC, SXCH and SSXC starter ranges are designed for anti-
clockwise rotation engines only, viewed from the flywheel end. In other words, the starter
replaces clockwise rotation electrical, pneumatic or hydraulic starters. (See Appendix II).
See Appendix V for modified operation of anticlockwise starter.

Engine Space:
Check that you have sufficient room on the engine crankcase to fit the starter.
(See Appendix I)

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 Startwell Getting Started

Replacing the Original Starter:

Remove the existing electric, pneumatic or hydraulic starting device, ensuring that you retain
any spacers already present, unless the starter model that you have already has a spacer
included with it.
Make sure that while removing the old starter you do not disconnect the fuel shut-off valve.
On some applications there may be an electrical engine shut-off valve. This can either be
operated by direct supply from the battery or converted to manual shut-off.

Startwell Design:
You may find when replacing your current starter with the Startwell Starter that there is a
difference between the numbers of teeth on the two pinions. This is a design feature adapted
to make a larger body diameter Startwell Starter
replaces a smaller diameter electric starter. This
Fig. 1
is achieved by offsetting the spigot and mounting
holes of the starter from its centreline and
increasing the number of teeth to compensate for
this.

Pre Installation checks:

The Startwell Starter is designed so that when
installed on the engine, in the unwound position,
there is between 3 and 5 mm clearance between
the pinion face and the flywheel ring gear. To
ensure that the clearance is correct, press the
‘check card’ (provided) against the ring gear and
ensure the flange mounting face sits in the green
area. (See Fig. 1)
Flange Mounting Face

Flywheel Ring Gear

Fig 2
Alternative: measure the mounting face to pinion face
dimension 'X', and the mounting face to ring gear depth 'Y'.
The distance Y-X should be between 3 and 5 mm. (See Fig 2)

Final Preparation: Mounting Face

To complete the installation tighten the nuts or bolts
(whichever is appropriate for your application) to the torque
recommended by the engine manufacturer.

The starter is assembled so that in the majority of applications

the winding handle is in a position suitable for you to wind the
starter comfortably. If this is not the case the angle of the
winding handle position can be changed to suit your needs.
See Position Code Procedure, page.8.

The Operating Instruction Sticker should be stuck close to the

engine, so that it is clearly visible to the starter operator.

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Startwell Getting Started

Operation
1. If the starter is fitted on a tractor or mechanical handling vehicle, such as a fork lift
truck or a loader, ensure that the gearbox is in the neutral position.
2. Ensure that the fuel is turned OFF.
3. Using the winding handle, rotate the winding adaptor until the WHITE spring is
visible in the window. Move the trip lever to the trip position.
4. The engine will rotate but not start. This will ensure that the starter is operating
normally.
5. Check the fuel valve is in the 'ON' position and that fuel is reaching the fuel pump.
6. Adjust the throttle to between 1/2 and 3/4 open.
7. The trip lever (with the red knob), of the starter, must be in an upright position. If
this is not the case, pull the reset knob (black). The trip lever will immediately
spring to its upright position.
8. When starting an engine fitted with an in-line pump for the first time, it may be
necessary to press the excess fuel button on the pump.
9. Fit the Cranking handle and wind the handle in a clockwise direction until red or
white springs are visible through the inspection windows (See Appendix II for
number of turns). With the white spring visible the starter is ready to start a warm
engine. With red springs visible the starter is ready to start a cold engine.
10. To start your engine, push the trip lever down through 90°.
11. If the engine does not start repeat the above steps. Your engine will normally start
within three attempts.

IMPORTANT: Do not attempt to start the engine with an electric or

other starter while the Startwell Starter is wound and engaged

Unwinding – Set Trip Lever to Vertical Position

If after fully winding the starter it is necessary to unwind and de-energize it, simply unwind
the crank handle in an anti-clockwise direction. It may be necessary, at first, to exert extra
force to disengage the clutch. Continue unwinding until green springs are visible through the
inspection windows. At this point the starter pinion will also retract to its rest position.

Slow Engine Cranking

The Startwell Starter can be used to slowly crank an engine, for the adjustment of tappets,
pump timing or equipment coupled to your engine. With the red trip lever in the upright
(downward for anticlockwise starter) position turn the winding handle clockwise for two turns.
This will engage the pinion with the ring gear. Now trip the lever through 90°. The black reset
knob will pull in and lock the red trip lever in this position. The engine can now be turned
slowly with the winding handle, and any adjustments, to the engine, may be made. Once
slow cranking is completed you should pull the black reset knob and either fully wind to start
the engine (see Operation) or unwind to disengage the pinion (see Unwinding).

Dual Starting Engines (See Appendix IV for important information)

Where the engine has the facility to be operated using two starters (electric starter and the
Startwell starter), the Startwell starter must have its pinion disengaged from the engine
flywheel when the alternative starter is being used. The pinion is disengaged by turning the
winding handle in an anticlockwise direction, until no further unwinding is possible. This also

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 Startwell Getting Started

applies to vehicles fitted with a Startwell starter that are being ‘bump’ started e.g. forklifts,
tractors.

Cold Starting
When starting at ambient temperatures below 0°C, it will be necessary to use some form of
starting aid. Starting can be achieved through various forms of ether-assisted aids which are
available in aerosol cans or as auto start kits.
To cold start proceed with normal starting operation. Prior to tripping, spray the ether into the
air intake, or if your engine is fitted with an auto start kit inject the ether inside the inlet
manifold. If the engine fails to start, repeat the whole operation immediately. The engine
should now start.

Trouble Shooting
(Components described in this section are illustrated in ‘The Startwell Starter, pg.3)

Operation of your Startwell Starter should be trouble free, as long as the starter has been
fitted correctly (see installation), and the correct engine and starter operation is adhered to
(see operation). If a problem does occur it is often possible for the operator to identify and
correct the situation.

Faulty Winding Mechanism

On turning the winding handle two turns in a clockwise direction the winding adapter should
rotate smoothly, thus causing the drive pinion to move forward and engage with the flywheel
ring gear. Further rotation should cause the spring pack to gradually compress as viewed
through the body inspection window.

FAULT CAUSE ACTION

Winding adaptor is jammed the bevel pinion is broken The bevel pinion must be
so that cranking handle will and is locking the drive replaced and the drive gear
not turn gear rotation checked for damage
Shims (part no. 20026) must
the meshing between the
Winding adaptor’s rotation is be added or removed from
bevel pinion and drive gear
‘stiff’ or not-smooth between the rear housing
is too tight
bearing and the drive gear
Winding adaptor rotates but
The bevel pinion or input
the spring core does not the bevel pinion or the input
shaft must be replaced
compress and the pinion and shaft is broken
core pack does not rotate.
the drive ratchet is broken
Winding the adaptor does Fit new ratchet or circlip as
or the circlip has come
not cause the spring pack to appropriate
loose
compress or the drive pinion
the pinion is jammed on the
to move forward to Burring can be removed with
drive shaft due to burring
engagement (the drive a grinding stone or a new
on five start thread or due
pinion does however rotate) drive shaft fitted
to excessive rust
Operation is normal up to Adjust lock to correct height,
compression of spring pack, the lock height is incorrect using lock height gauge (part
but starter then discharges no. ST 123A),
prematurely before pack is the lock and/or ratchet are
Replace worn component(s)
fully compressed worn

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Startwell Getting Started

Jammed Starter

FAULT CAUSE ACTION

The drive shaft or drive nut Set Trip Lever to vertical

The starter jams during
threads are worn causing position. Turn the Winding
compression of the spring
the ball bearings to jam Adaptor anti-clockwise,
pack or fails to discharge on
between the nut and the until the green spring is
tripping
shaft visible through the
window.

IF the starter still cannot be Place the starter in a strong wooden box and contact
discharged Startwell for further instructions.

WARNINGCode
Position DO notTab
attempt to dismantle a jammed starter as this is extremely
dangerous and requires expert attention. Keep your fingers away from the
pinion. Only lift the starter by the red trip lever. Contact your local agent.

Position Code Procedure

The winding handle position relative to the angle of the nosepiece can be rotated through
360°, in 8.5° steps, to achieve the best winding position. Starters are made to a pre-set
position in the factory that should be right for your application. If, however, you require an
alternative position follow the steps below:

1. For the factory built position code, refer to outline or Clockwise is ‘+’ angle
general arrangement drawing. Anti-clock is ‘-‘ angle

2. For an alternative position code, decide on the angle Datum

between the release lever and input adaptor to suit your line
application (e.g. your selected angle = +10°). - +
8.5
3. Select the nearest position code from the table below (e.g.
8.5°+ = 2B).
4. To achieve the selected (2B) position code, align the hole
next to the letter '0' at the front end of the body, against
the hole designated '2' on the front housing. Use the
correct through bolt to secure the front mounting bracket,
the housing and the body in this position. (Note: For
starter without separate mounting bracket secure housing
assembly to the body).
5. Place the rear housing on the body and align the radial
hole 'B' against the letter '0' on the body. Secure the body
and the rear housing in this position.
Fig. 3 Position
6. Fit the remaining screws and tighten to a torque of 6-8 Code 2B
Nm.

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 Startwell Getting Started

Position Code Table

Code Angle '+' Code Angle '-'
1A 0 1A 0
2B 8.6 6G 8.6
3C 17.1 5F 17.1
4D 25.7 4E 25.7
5E 34.2 3D 34.2
6F 42.9 2C 42.9
1G 51.4 1B 51.4
2A 60 6A 60
3B 68.6 5G 68.6
4C 77.1 4F 77.1
5D 85.7 3E 85.7
6E 94.2 2D 94.2
1F 102.9 1C 102.9
2G 111.6 6B 111.6
3A 120 5A 120
4B 128.6 4G 128.6
5C 137.1 3F 137.1
6D 145.7 2E 145.7
1E 154.2 1D 154.2
2F 162.9 6C 162.9
3G 171.4 5B 171.4
4A 180 4A 180

Position of 0 - 0' Release Lever

Stamping on the body
Winding Adapter

A 1
G B
6 2

F C
5 3
E D
4

Fig. 4 Fig. 5 Fig. 6

Note: The six through holes on the front housing are designated by numbers 1 to 6
clockwise, looking from the rear of the housing (fig.6). The seven radial tapped holes on the
rear housing are designated by letters A to G clockwise, looking from the rear of the housing
(fig.4). On the starter body, only two of the holes at either end are in line. These are marked
with ‘O’ next to each hole (fig 5).

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Startwell Getting Started

Appendix I: Starter Sizes

L (mm) D1 (mm) D2 (mm)

MINI 259 110 114
MIDI 285 115 118
HEAVY DUTY 285 115 127
MAXI 329 117 130
HEAVY DUTY MAXI 329 133 136
SUPER MAXI 346 133 140.5

Appendix II: Starter Specifications

HEAVY
HEAVY SUPER
Range MINI MIDI MAXI DUTY
DUTY MAXI
MAXI
Clock SNC SDC SDCH SXC SXCH SSXC
Model A/Clock SNA SDA SDAH SXA SXAH SSXC
SAE 1, SAE 1, SAE 1, SAE 1, SAE 1,
SAE 1
Mounting Flange SAE 2, SAE 2, SAE 2, SAE2, SAE 2,
SAE 4
SAE 3, SAE 3, SAE 3 SAE3 SAE 3
Litre /
0.5 1.1 1.3 1.5 2 2.3
cylinder
Capacity Max no.
4 6 6 6 6 6 (8)
cylinders
Pinion
123 156 171 171 198 199
Max (Nm)
Torque Winding
81 87 95 95 102 109
(Nm)
Weight (Kg) 12 16 18 20 22 25
Turns to
7.5 10 10 13.5 14 16
fully wind

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 Startwell Getting Started

Appendix III
Parts List

16
1. Mounting Flange 18 Input Adaptor 36. Drive Ratchet 56. Lock Stop
1A. Mounting Bracket 19. Friction Washer 37. Spring Locating Disc 57. Release Lever
2. Lock Housing 20. Input Ratchet 38. Return Spring 58. Lock Nut
3. Body 21. Input Shaft 39. Spring Locator 59. Hand Grip
4. Window 22. Thrust Washer 40. Ball Bearing 60. Reset Assembly
5. Washer 23. Bush 41. Drive Pinion 61. Gasket
6. Screw 24. Input Gear 42. Thrust Washer 43,44 62. Cover Plate
7. Rear Housing 25. E-Clip 45. Bush 63. Spring Washer
8. Plug 26. Shim 46. Swivel Pin 64. Screw 65,66,67,68
9. Screw 27. 'O' Ring 47. Lock Pin 69. Bellows
10. Shim 28. Drive Gear 48. Lock 70. Hand Grip
11. Support Plate 29. Drive Spring 49. Bush 71. Rear Plug
12. Nut 30. Drive Ring 50. Bush 72. Distance Collar
13. Lock Washer 31. Drive Nut 51. Link Assembly 73. Cranking Handle
14. Stud 32. Ball Bearing 52. Release Shaft 74. Distance Piece
15. Catch Spring 33. Cage 53. Return Spring
16. 'O' Rings 34. Drive Shaft 54. 'O' Ring
17. Catch 35. Circlip 55. Lock Washer

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Startwell Getting Started

Parts List for Tool Kit

Part no. Description

SWT 138/2 Base Plate Feet 1
SWT 138/1 Base Plate 2
SWSH Socket Headed Screw 3
SWT 121 Spacer 4
SWT 138/3 Pillar 5
SWT 122 Press Tool 6
SWT 138/4 Pressure Plate 7
SWT 138/5 Handle Assembly 8

SWT 123 Lock Setting Gauge

SWC P1 External Circlip Pliers

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 Startwell Getting Started

Appendix IV: Important Operating Instructions

Storage Mounting

It has come to our attention that on

some vessels during regular periodic
maintenance on the emergency Gen-
set, the Startwell stand-by starter types
SXC047 and SXCH047 are being
tested when fitted on the storage
bracket next to the engine.

This is causing serious internal damage

to the starter and resulting in premature
failure when later used on the engine.

The starter should NOT be tested on the storage bracket under any
circumstances. The starter may only be operated when properly fitted to the
engine.

Any damage caused by this action will not be covered under warranty.
This bulletin does not apply to starters fitted permanently on any engine.

Instructions for 'Dual -Start Engines'

On engines fitted with dual starting system, such as

electrical and manual starter, the manual starter
must not remain engaged with Flywheel when starting
with the electric starter. Or when the engine starts
automatically with electrical starter (such as on a ships
emergency generator)

To ensure the starter is not engaged, leave the trip-

lever in the trip position when the starter is not in use.
This will ensure that the starter pinion is not engaged
with the engine flywheel

Failure to follow this action may damage the Starter.

Any damage caused by this action will not be covered
under warranty.

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Startwell Getting Started

Appendix V: Anti-clockwise starters

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 Startwell Getting Started

Appendix VI: Routine Testing of Startwell Starter

It is important to establish that the pinion has returned to its rest position (out of
Engagement) after routine testing has been carried out. See instructions on the right.

Whilst winding, if the engine DOES rotate then please follow the procedure below;

1. With the ‘Trip’ lever this time in ‘Reset Position’ unwind the starter anti-clockwise 2-
3 turns
2. The Pinion will retract back to its Rest position (out of Engagement).
3. Once the above steps have been carried out, with the Trip Lever in ‘Trip’ position,
wind the starter clock-wise to ensure the Pinion is disengaged with flywheel ring-
gear.
4. Rotate the winding handle a few more turns.
5. Observe that the GREEN spring is rotating and there is no rotational movement of
the engine crankshaft.
6. If the engine crankshaft rotates, remove the starter from the engine.
7. Contact Startwell Engineering, supplying full details by email to [email protected]

IMPORTANT NOTICE

15
5 Crystal Centre, Crystal Way, Tel: +44 (0)20 8863 4450
Elmgrove Road, Harrow Fax: +44 (0)20 8863 4410
Middlesex, London HA1 2HP Email: [email protected]