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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

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 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.

In addition to the starter unit you should have received:

• one winding handle,

• a copy of the 'Getting Started' operators
instruction booklet,
• operating instruction sticker,
• cardboard check-gauge

Contact information:

Startwell Engineering UK Limited, Unit 1A, Phoenix Trading Estate,

Rosslyn Crescent, Harrow, Middlesex, HA1 2SP. United Kingdom.

Tel +44 (0)20 88634450 Fax +44 (0)20 88634410

Email [email protected]

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 The Startwell Starter

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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
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 be negated.

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:
The SNC, SDC, SDCH, SXC and SSXC starters 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)

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

Replacing the Original Starter:

b) 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.
c) 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:
d) You may find when replacing your current starter with the Startwell Starter that there is a
difference between the number of teeth on the two pinions. This is a design feature
adapted to make a larger body diameter
Startwell Starter replace a smaller diameter
Fig. 1
electric starter. This 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 check:

e) 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
Flange Mounting Face the flange mounting face sits in the green
area. (See Fig. 1)
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) Mounting
Face
Final Preparation:
g) 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, pg.8. Ring
Gear
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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Operation
Ring Gear
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. Check the fuel valve is in the 'ON' position and that fuel is reaching the fuel pump.
3. Adjust the throttle to between 1/2 and 3/4 open.
4. 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.
5. 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.
6. 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.
7. To start your engine, push the trip lever down through 90°.
8. If the engine does not start repeat the above steps. Your engine will normally start
within three attempts.

IMPORTANT. Do not attempt to start your engine with an electric

or other starter while the Startwell Starter is wound and engaged

Unwinding
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 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 (for example an air 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 applies to vehicles fitted with a Startwell starter that are being ‘bump’ started e.g. forklifts,
tractors). For important additional instructions see appendix III.

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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 the 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 adapter is jammed the bevel pinion is broken The bevel pinion must be
so that cranking handle will and is locking the drive gear replaced and the drive gear
not turn rotation checked for damage
Shims (part no. 20026) must
the meshing between the
Winding adapter’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 adapter 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.
Winding the adapter does not the drive ratchet is broken or Fit new ratchet or circlip as
cause the spring pack to the circlip has come loose appropriate
compress or the drive pinion the pinion is jammed on the
Burring can be removed with
to move forward to drive shaft due to burring on
a grinding stone or a new
engagement (the drive pinion five start thread or due to
drive shaft fitted
does however rotate) 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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Jammed Starter

FAULT CAUSE ACTION

unwind the starter by turning
the drive shaft or drive nut
The starter jams during the winding handle in an
threads are worn causing
compression of the spring anti-clockwise direction, until
the ball bearings to jam
pack or fails to discharge on the green springs are visible
between the nut and the
tripping through the inspection
shaft
window
IF the starter still cannot be Place the starter in a strong wooden box and contact
discharged Startwell for further instructions.

WARNING DO not 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 8.6° 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
Datum
2. For an alternative position code, decide on the angle
between the release lever and input adapter to suit line
your application (e.g. your selected angle = 10°). - 8.5
+
3. Select the nearest position code from the table
below (e.g. 8.6° = 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 Fig. 3 Position
position. Code 2B
6. Fit the remaining screws to a torque of 6-8 Nm.

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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

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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 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
SUPER MAXI 346 133 140.5

Appendix II: Starter Specifications

HEAVY SUPER
Range MINI MIDI MAXI
DUTY MAXI
Clock SNC SDC SDCH SXC SSXC
Model A/Clock SNA SDA SDAH SXA SSXC
SAE 1, SAE 1, SAE 1, SAE 1,
SAE 1
Mounting Flange SAE 2, SAE 2, SAE 2, SAE 2,
SAE 4
SAE 3, SAE 3, SAE 3 SAE 3
Litre /
0.5 1.1 1.3 1.5 2 (1.5)
cylinder
Capacity Max no.
4 6 6 6 6 (8)
cylinders
Pinion
91 115 126 126 147
Max (Nm)
Torque Winding
60 64 81 81 94
(Nm)
Weight (Kg) 12 16 18 20 25
Turns to
Ring fully wind 7.5 10 10 13.5 16
Gear

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

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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

SWT PG1 Pinion Gauge
SWC P1 External Circlip Pliers

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 Appendix III: Urgent Operating Instructions

1. 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 type 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 on 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.

2. Dual Starting Engines

For dual starting engines, the

Startwell Starter must not be
engaged when operating the electric
starter. This will result in severe
damage to the starter.

Startwell starter should be left in the

TRIP position – by rotating the trip
handle. This will ensure that the
starter pinion is not engaged with
the engine flywheel.

Standard RESET and TRIP position.

These positions may vary depending on your application.

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

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