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IPU Spring Starter, Operator'S Manual

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IPU Spring Starter Operator'S Manual Download Page 8

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Pre Installation checks 

The IPU 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’ (provide

d) against the ring gear and ensure 

the flange mounting face sits in the safe area. 

  

  

 

 

 
 
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. 

 
 

 

 

  

Flywheel Ring Gear 

Flange Mounting Face 

  

  

 

 

 

 

Summary of Contents for Spring Starter

Page 1: ...Spring Starter Operator s Guide Production Release July 2017 Version 2 00 Original Version English ...

Page 2: ...Final Preparation 9 Operation 10 Unwinding 11 Slow Engine Cranking 12 Dual Starting Engines 13 Cold Starting 14 Trouble Shooting 15 Faulty Winding Mechanism 15 Jammed Starter 16 Position Code Procedure 17 Position Code Table 18 Appendix 1 Replacement Parts List 19 Appendix 2 Important Operating Instructions 20 Storage Mounting 20 Instructions for Dual Start Engines 21 Appendix 5 Anti clockwise Sta...

Page 3: ...pu co uk starting This booklet provides you with all the information you need to install and operate your IPU SureStart Spring Starter Please note once fitted it is important to rotate the engine before using the spring starter for the first time This is to ensure the spring starter is installed correctly and reduces the risk of damage to the engine and the starter motor Instructions on how to do ...

Page 4: ...l reset button 2 Wind clockwise 1 turns 3 Operate the trip lever 4 Continue winding 5 Operate starter for 1 complete engine revolution The above steps ensure the Spring Starter is fitted correctly and will not cause damage to the starter or the engine If any of the above steps cannot be completed please contact IPU on 44 0 121 511 0460 for further support DO NOT OPERATE THE STARTER WITH ENGINE DEC...

Page 5: ... 4 Open throttle 5 Pull reset button 6 Wind clockwise until RED springs are showing WHITE springs visible unwound RED springs visible wound for starting 7 Operate the trip lever TO UNWIND STARTER Crank the handle in an anti clockwise direction until the WHITE springs appear in the inspection window CAUTION Do not dismantle or remove starter from engine unless WHITE springs are visible ...

Page 6: ...ing 5 Reset Knob 9 Spacer Shims 13 Circlip 2 Viewing Window 6 Input Adaptor 10 Drive Gear 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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 ...

Page 7: ...nkcase to fit the starter see Appendix I 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 e...

Page 8: ...on 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 safe area 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 Flywheel Ring Gear Flange Mounting Face ...

Page 9: ...ter 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 The Operating Instruction Sticker should be stuck close to the engine so that it is clearly visible to the starter operator ...

Page 10: ...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 springs are visible thr...

Page 11: ...rter motor 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 white springs are visible through the inspection windows At this point the starter pinion will also retract to its rest position ...

Page 12: ...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 eng...

Page 13: ...d the IPU starter the IPU 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 IPU starter that are being bump started e g forklifts tractors ...

Page 14: ...f 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 ...

Page 15: ...aptor s rotation is stiff or not smooth The meshing between the bevel pinion and drive gear is too tight Shims part no 20026 must be added or removed from between the rear housing bearing and the drive gear Winding adaptor rotates but the spring core does not compress and the pinion and core pack does not rotate The bevel pinion or the input shaft is broken The bevel pinion or input shaft must be ...

Page 16: ...t trip lever to vertical position Turn the Winding Adaptor anti clockwise until the white springs are visible through the window If the starter still cannot be discharged Place the starter in a strong wooden box and contact IPU for further instructions WARNING Do NOT attempt to dismantle a jammed starter as this is extremely dangerous and requires expert attention Please contact your local IPU age...

Page 17: ... to suit your application e g your selected angle 10 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 star...

Page 18: ... 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 sta...

Page 19: ...P a g e 19 Appendix 1 Replacement Parts List 1 Mounting bracket assembly 2 Core assembly 3 End housing assembly 4 Cranking handle assembly 5 Pinion 1 2 3 4 5 ...

Page 20: ...es serious internal damage to the starter and will result in premature failure when later used 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 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 ...

Page 21: ...arts 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 Reset ...

Page 22: ...hand crank clockwise until red springs show in sight glass Remove hand crank Push trip lever to start engine Turn hand crank counterclockwise until white springs show in sight glass Caution Do not dismantle or remove starter from engine unless fully unwound Once the spring starter is energised it must be released or unwound Do not attempt to use electric start with spring starter energised ...

Page 23: ...i clockwise 2 3 turns 3 The Pinion will retract back to its Rest position out of Engagement 4 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 5 Rotate the winding handle a few more turns 6 Observe that the WHITE spring is rotating and there is no rotational movement of the engine ...

Page 24: ...P a g e 24 Contact Details IPU Group Cygnus Way West Bromwich West Midlands B70 0XB United Kingdom Phone 44 0 121 511 0460 Fax 44 0 121 511 0401 Web www ipu co uk starting Email ipu ipu co uk ...

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