IPU Spring Starter Manual

Spring Starter Operator’s Guide
Production Release: July 2017
Version 2.00
Original Version: English

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Contents
Introduction .................................................................................................................................................................3
Contents of Box .....................................................................................................................................................3
Before using the Spring Starter for the first time..............................................................................................4
Basic steps....................................................................................................................................................................5
The IPU Spring Starter ..............................................................................................................................................6
Installation....................................................................................................................................................................7
Rotation....................................................................................................................................................................7
Engine Space ..........................................................................................................................................................7
Replacing the Original Starter............................................................................................................................7
IPU Design...............................................................................................................................................................7
Pre Installation checks..........................................................................................................................................8
Alternative................................................................................................................................................................8
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 Starters....................................................................................................................22
Appendix 6: Routine Testing of IPU Starter......................................................................................................23
Contact Details..........................................................................................................................................................24

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Introduction
Thank you for purchasing the IPU Spring 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.ipu.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 this are on page 5.
Contents of Box
•Starter motor
•Winding handle
•Getting started user manual
•Operating instruction stickers, as required
•Check card
•Bolts/nuts/spacer, as required

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Before using the Spring Starter for the first time
Before you operate the IPU SureStart Spring Starter for the first time you must complete the
following:
TO ROTATE THE ENGINE WITHOUT STARTING
1. Pull reset button
2. Wind clockwise 1¾ 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 DECOMPRESSED

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Basic steps
After you have completed the preparation steps on page 4 below are the basic operating
procedures:
TO START
1. Gearbox must be in neutral
2. Fuel on
3. Set excess fuel
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.

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The IPU Spring Starter
1
Front Housing
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

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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 IPU 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 starter ranges are designed for anticlockwise 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).
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.
IPU Design
You may find when replacing your current starter with the IPU 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 IPU Starter replaces a smaller diameter 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.

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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’ (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

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Final Preparation
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.
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
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 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 springs are
visible through the inspection windows (See Appendix II for number of turns). With the
RED spring visible the starter is ready to start the 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 IPU
Starter is wound and engaged.