Engine Starting Solutions

Spring starter
workshop
manual

Simms SM series (Stubby) starter motor

Simms SZ series Z drive starter motor
Simms SZH2 series starter motor
 i Index

Page

Method of operation 2
Assembly information 5
Component inspection & renewal 13
Re-assembly information 17
Fitting of sub-assemblies 32
Testing 37
Torque values 39
Parts Lists 40

For more information on the IPU Fuel Polishing Buggy please contact
Jonathan Hickman on Tel: +44 (0) 121 511 0400 or
Mobile: +44 (0) 7989 678325 or Email: [email protected]
END HOUSING
The end housing (2) is a cast unit incorporating a winding adaptor (25), for turning the winding
shaft (22), bevel pinion (1), friction discs (23) and ratchet disc (26). The ratchet disc engages with
two spring loaded pawls (27) which are diametrically opposite to each other and prevent reverse
rotation of the winding shaft. The bevel pinion is mounted on the end of the winding shaft and
engages with the bevel gear integral with the spring sleeve (20).

The winding mechanism within the end housing ensures that the starter can be safely and easily
unwound, should it be required. This is achieved by the design of the ratchet disc and the winding
adaptor which is mounted on a screw thread. During winding, the adaptor screws down and locks
the ratchet disc on the shaft. When the adaptor is unwound, the lock is broken and the energy
stored in the spring core assembly (20), (21) is slowly released

SPRING CORE ASSEMBLY

The carcase (4) houses the spring core (21) which consists of 24 steel discs of concave/convex
form assembled on the spring sleeve (20).

The spring discs, when compressed by the manual action of the winding shaft, provide a
considerable source of potential energy.

The peripheries of seven of the spring discs are painted so that the colours, as seen through the
inspection window (5), indicate visually the amount of energy stored in the spring.

Rotating the spring sleeve compresses the spring discs between the flange on the sleeve and the
four lugs of the ball nut (17) which slide in slots in the sleeve. Steel balls in the cage (18) engage
with the threaded ball nut and corresponding threads on the mainshaft (19).

The starter pinion (13) has an integral sleeve which functions as a cage for the steel balls (15). The
balls are held captive by recesses in the ratchet ring (16) and engage screw threads on the
mainshaft. During winding, rotation of the mainshaft moves the pinion into engagement with the
engine flywheel ring gear. When the starter has discharged, the pinion is automatically
disengaged from the ring gear assisted by the return spring (14).

The mainshaft is supported by a bush in the nosepiece and by steel balls in the ball seat (3) of the
spring sleeve. Support for the spring sleeve is provided by a plain bearing which forms part of the
end housing (2).

NOSEPIECE
A cast iron nosepiece carries the catch housing (9), the trip lever mechanism and reset button (6).
These respectively control the release of the spring core energy and restore the position for re-
winding of the starter after tripping.

A trip lever (7) is provided for releasing the stored energy of the starter through the pinion to rotate
the engine flywheel. The re-set button operates to re-engage the pawl (10) with the pinion ratchet
(16).

METHOD OF OPERATION
WINDING
The Spring Starter utilises potential energy stored in the spring coil. This energy is provided by
compressing the spring discs by means of an external winding handle fitted to the winding
adaptor.

The sequence of operation is as follows:-

Depress and release the re-set button (6). Fit the winding handle (see fig.1 and turn in a clockwise
direction.

page 2
During the initial stage of the winding operation, 1¾ turns, the bevel pinion (1) on the winding shaft
(22) rotates the bevel gear of the spring sleeve (20). This rotation is transmitted to the ball nut (17)
by the lugs in the slots in the spring sleeve (20) and then to the mainshaft (19) via the steel balls in
the screw thread. Thus the shaft nut and sleeve all rotate together.

The starter pinion (13), which is connected to the mainshaft by the steel balls (15), is restrained from
rotating by the friction load of the pawl (10) on the pinion ratchet (16).

As the mainshaft continues to rotate, the screw action of the five start thread on the shaft and the
accompanying five steel balls moves the pinion forward into mesh with the engine flywheel ring
gear. Whereupon, the pawl (10) locks into the ratchet ring (16) and prevents the mainshaft from
rotating.

Since the mainshaft is now fully locked, further winding turns only the spring sleeve and ball nut
assemblies. This screws the ball nut and ball cage (18) along the mainshaft thread.

The spring discs (21) are thus compressed until the white painted discs can be seen through the
inspection window (5): white indicating sufficient stored energy to start a warm diesel engine.

One more turn of the winding handle after the white disc is visible will fully compress the spring discs
and display the red discs through the inspection window. The red discs indicate the fully wound
condition for starting a cold diesel engine.

TRIPPING
When the starter is wound, with either the white or red edge discs visible in the inspection window
(5), the spring discs are compressed by the ball nut (17). This is prevented from rotating by the
spring sleeve (20) which is held by the ratchet disc (26) and pawls (27) on the winding shaft (22).
The mainshaft is similarly held stationary because the starter pinion (13), which is connected to the
shaft by the steel balls (15), is locked by the ratchet ring (16).

Movement of the trip lever (7) through 900 in the direction indicated by the arrow on the trip lever
boss lifts the pawl (10) clear of the ratchet ring (16) and allows the elongated hook (8) to engage
with the catchplate. The hook thus holds the pawl clear of the ratchet during operation of the
starter so permitting the mainshaft to rotate.

As the stored energy is thus released by the trip lever, the discs push the ball nut (17) forward,
transmitting the axial movement to the ball cage (18) which via the steel balls in the screw thread
rotates the mainshaft and pinion (13) to start the engine.

This release of energy is almost instantaneous and is sufficient to turn the engine flywheel
approximately 1½ revolutions at high speed.

When the mainshaft comes to rest, the engine flywheel overruns the pinion which is then thrown
out of engagement and returns to its discharged position where it is retained by the return spring
(14).

UNWINDING

If unwinding is necessary, due to an engine fault, for example the starter may be unwound and the
main spring load gradually released by turning the winding handle on its spindle in an anti-
clockwise direction.

The mechanism which makes this unwinding operation possible is the friction loaded ratchet disc
(26) on the winding shaft (22).

Two friction discs (23) are located one each side of the ratchet disc which in turn reacts with the
two pawls (27). One friction disc abuts the winding adaptor (25) and the other a shoulder on the
winding shaft.

page 3
During winding, the winding adaptor screws down the thread on the winding shaft and clamps the
ratchet disc. When unwinding, the adaptor is partially unscrewed from the winding shaft and
pressure is reduced on the friction discs so allowing the winding shaft to rotate inside the ratchet
disc. At this point the mainshaft is locked by the pinion ratchet (16) and Pawl (10), so the spring
load moves the ball nut both axially and rotationally along the threaded mainshaft.

Since the spring sleeve is rotated by the ball nut this in turn rotates the winding shaft through the
bevel gears until the load on the friction discs increases and grips the ratchet.

Thus as the unwinding proceeds, the spring discs apply pressure and compel the winding shaft to
rotate at the same speed as the adaptor being rotated by the winding handle, until the spring
load is completely released and the green spring discs appear in the inspection window.

SLOW ENGINE CRANKING

To facilitate adjustments of the tappets, bleeding the fuel system of air and timing of the fuel pump
etc., the starter may be used to rotate the engine slowly and easily.

To operate, press and release the reset button, then rotate the winding handle 1¾ turns to engage
the starter pinion with the engine flywheel ring gear. When the trip lever is moved through the full
900 of movement, the engine can then be rotated as the winding handle is turned.

To reset the starter for normal use, press and release the reset button.

Warning Note: The spring starter must NEVER be operated unless fitted to an
engine or mounted on a test rig designed to safely absorb the stored energy
when the starter is tripped. Failure to observe this precaution will result in internal
damage to the starter.

A high reservoir of energy is stored in a fully wound spring starter and it is

mandatory that all starters should be unwound before removal from an engine or
test-rig. An unwound starter may be recognised by the green spring disc visible
through the inspection window. Additionally the pinion should be fully
disengaged from the flywheel ring gear.

page 4
REMOVAL OF SUB-ASSEMBLIES

Note: for ease of dismantling the starter should be stripped down into three sub-
assemblies, these are as follows:-

End Housing;

Spring Core;

Nosepiece/Carcase.

WARNING
Before dismantling the starter the following safety precautions MUST be observed:-

1. Ensure the starter main spring is unloaded, by checking that the green painted spring
discs are visible through the inspection windows.
2. If the green painted discs are not visible, the starter must be unwound as described
under “DESCRIPTION “ - “UNWINDING”.
3. The carcase of the starter must NOT be gripped in a bench vice, since this can cause
distortion, and so affect essential clearances.

END HOUSING FROM CARCASE

Fig.3 Removal of end housing from carcase

Key to Numbers:-
1. Winding adaptor 4. End housing 7. Cap screw and spring washer 10. Carcase 13. Plastic plug
2. Locknut and tab washer 5. Cover plate 8. Carcase shim, when fitted 11. Trip lever 14. Allen screw
3. Top plate 6. Screw and spring washer 9. Shim- bevel gear 12. Stand, tool Part No. ST120 15. Lead seal/tab

page 5
Make a note of the starter assembly code position or alternatively scribe a line across the
end housing/carcase and nosepiece/carcase joints to enable these parts to be
correctly aligned on re-assembly.

Position the starter vertically on end with the nosepiece downwards on the stand, tool
Part No. ST120. Screw the winding adaptor (1) approximately one complete turn anti-
clockwise to release the winding ratchet friction. Remove the plastic plug (13) from the
winding adaptor.

Unlock the legs on the tab washer (2) and slacken the nuts on the top plate (3). Slacken
the hexagon screws and spring washers (6) on the cover plate (5).

Slacken the Allen screw (14) in the winding adaptor. Break the seal on the locking tab
(15) and remove the tab, six cap screws and spring washers (7) securing the end housing
(4) to the carcase (10).

Lift off the end housing, use a rawhide mallet to dislodge the housing if necessary.
Remove the carcase shim (8), if fitted, and extract the shims (9) from the recess in the
bevel gear.

SPRING CORE ASSEMBLY FROM CARCASE

Operate the trip lever (5) through its full travel of 90 degrees to engage the hook in the
catchplate.

Place a hand over the open end of the carcase (2) to retain the spring core assembly (3)
and invert the carcase.

Lower the starter, bevel wheel downwards, on to a workbench. Then, holding the trip
lever in the fully tripped position, lift the carcase and nosepiece assembly vertically off
the mainshaft, leaving the spring core assembly on the bench.

Note: On type SS39-1 starters a flat is machined on one side of the support bearing (1),
see Fig.6, to enable the bearing to pass under the pawl in the nosepiece.

When removing the carcase and nosepiece assembly, ensure the trip lever is in the fully
tripped position and ease the carcase from the mainshaft by slowly rotating the
assembly until it is free to be withdrawn.

CARCASE FROM NOSEPIECE

Invert the carcase and nosepiece assembly so that the open end is uppermost and fit
the nosepiece into the stand, tool Part No. ST120.

Using the extended Allen key, tool Part No. ST129 and 3/16 in. Whitworth spanner,
unscrew the six socket head screws and spring washers (4) securing the carcase to the
nosepiece assembly.

Separate the carcase from the nosepiece assembly, tapping it loose with a rawhide
mallet if necessary.

page 6
Fig.4 Method of removing spring core assembly

Key to Numbers:-
1.Nosepiece
2. Carcase
3. Spring core assembly
4. Socket head screw and spring washer
5. Trip lever

END HOUSING ASSEMBLY (See Fig.5)

Unscrew and remove the previously slackened nuts (1) and tab washers (2) securing the
top plate (3).

Fig. 5 Exploded view of end housing showing differences between clockwise and anti-clockwise winding shaft assemblies
Key to letters and Numbers:-
A. Clockwise rotation
B. Anti-clockwise rotation
1. Locknut 12. Bush- winding shaft 23. Plastic plug
2. Tab washer 13. Joint 24. Retaining clip
3. Top plate 14. Cover plate 25. Thrust washer
4. Pawl spring 15. Screw and spring washer 26. Bushes- winding shaft
5. Pawl 16. Bevel pinion 27. Distance piece
6. Ratchet disc 17. Circlip 28. Bevel pinion
7. Winding shaft 18. Bush-winding shaft 29. Distance collar
8. Thrust washer 19. Friction discs 30. Winding shaft
9. Allen cap screw and spring washer 20. Winding adaptor
10. Locking tab and lead seal 21.Rubber ‘O’ rings
11. End housing 22. Retaining screw

page 7
Position the complete end housing (11) so that the flats on the top plate can be gripped
between the soft jaws of a vice and, with a rawhide mallet, tap the end of the winding
adaptor (20) until the housing is clear of the plate.
Release the top plate from the vice and remove and discard the two rubber “O” rings
(21) from the internal diameter of the plate.

Prise the legs of the two springs (4) clear of the ratchet pawl (5) and lift both springs and
pawls form the housing.

From the opposite side of the housing, remove the two screws and spring washers (15),
cover plate (14) and joint (13).
On starters of clockwise rotation, remove the ‘E’ type circlip (17) retaining the bevel
pinion (16).

Withdraw the winding shaft (7), complete with adaptor (20) from the housing, followed
by the thrust washer (8) and bevel pinion.

On starters of anti-clockwise rotation, remove the retaining clip (24) and thrust washer
(25).

Withdraw the winding shaft (30), complete with the adaptor (20) from the housing,
followed by the distance collar (29), bevel pinion (28) and distance piece (27).

On both types of starter, unscrew and remove the previously slackened retaining screw (22)
from inside the winding adaptor. If the screw is tight, fit the tool, Part No. ST148, over the
hexagon flats on the end of the shaft and clamp the tool vertically between the soft jaws of the
vice. Remove the winding adaptor (20) from the shaft (7) and then remove the two friction discs
(19) and ratchet disc (6).

SPRING CORE ASSEMBLY (See Figs. 6,7 and 8)

Note: there are two sizes of ball diameters used in the spring core assembly. Ensure when
removing the balls that they are kept together in their respective assemblies.

Detach the disc spring (12) and thrust washer (11) from the end of the mainshaft (4).
Lay the assembly on a bench and release the circlip (5) from its groove in the starter pinion (10).

Holding the pinion in one hand, slide the ratchet ring (6) towards the spring pack and remove the
five steel balls (13) from the pinion sleeve. Slide the pinion, spring retainer (9), or support bearing
(1) if long nose starter, return spring (8), spacing ring (7), ratchet ring (6) and the circlip from the
mainshaft.

Note: On short nose starters for marine application or oil sealed types, seal housing (16) is
fitted in place of the spring retainer (9). On long nose starters, a support bearing (17) is
fitted. Remove the seal housing, or support bearing, and discard the inner and outer
rubber “O” rings (14) and (15).

page 8
Fig.6 Exploded view of pinion assemblies showing differences between long and short nose starters, marine application and oil sealed types

Key to Numbers:-
1. Support bearing – long nose starter
2. Long pinion – long nose starter
3. Spring core assembly
4. Mainshaft
5. Circlip
6. Ratchet ring
7. Spacing ring
8. Return spring
9. Spring retainer – short nose starter
10. Short pinion – short nose starter
11. Thrust washer
12. Disc spring
13. Five 7mm diameter steel balls
14. Inner rubber ‘O’ ring – marine application and oil sealed
15. Outer rubber ‘O’ ring – marine application and oil sealed
16. Seal housing-short nose starter – marine application and oil sealed
17. Support bearing-long nose starter

Fig. 7 Exploded view of spring core assembly

Key to Numbers:-
1. Ball seat
2. Rubber “O” ring
3. Spring sleeve
4. Spring discs
5. Steel balls
6. Steel balls
7. Mainshaft
8. Ball cage
9. Ball nut
10. Ball nut ring

page 9
 Fig. 8 Method of compressing the spring core assembly
Key to Numbers:-

1. Special press, tool Part No. ST138

2. Bridge piece, tool Part No. ST122
3. Spring discs
4. Spacer, tool Part No. ST 121
5. Steel balls

Using the special press (1), tool Part No. ST138, as shown in figure 7, hold the press in an
upright position and clamp the legs of the press between the jaws of a vice.

Slide the spacer (4), tool Part No. ST121, over the pinion end of the mainshaft and place
the assembly bevel gear uppermost in the press as shown in figure 7. Place the bridge
piece (2), tool Part No. ST122, into the recess in the bevel gear and clamp the top part of
the press with the two locknuts.

Screw down the press until the main spring discs (3) and ten steel balls (5) are depressed
approximately 9.5mm (3/8 in). With the pressure maintained, extract the steel balls from
the groove at the top of the mainshaft. Do not release the pressure on the spring core
until all the balls have been removed.

After slowly releasing the pressure, remove the assembly from the press.

Referring to figure 8, stand the spring core assembly upright on a bench with the shaft
uppermost and withdraw the shaft, complete with ball nut (9) and ball cage (8) from the
spring sleeve (3).

Holding the ball cage, unscrew the ball nut from the main shaft. Slide the ball cage
axially along the shaft to remove the sixteen steel balls (6) followed by the ball cage.

Remove the ball nut ring (10) and discs (4) from the spring sleeve (3).

page 10
 Fig.9 Exploded view of nosepiece assembly
Key to Numbers:-
1. Screw and spring washer 14. Link pin
2. Catch housing 15. Pawl pin
3. Joint 16. Plunger sleeve
4. Catch plate 17. Link plunger
5. Joint 18. Spring
6. Stop screw and spring washer 19. Top link
7. Nosepiece 20. Locknut
8. Needle roller bearing 21. Trip lever
9. Pawl pin bushes 22. Knob
10. Rubber ‘O’ ring 23. Return spring
11. Trip lever shaft 24. Trip lever shaft bush
12. Elongated hook 25. Rubber sealing bellows
13. Pawl

NOSEPIECE ASSEMBLY (See Figs. 9 and 10)

Locate the nosepiece (7) in the stand, tool Part No. ST120, and press the reset button (25)
to release the elongated hook (12) from the catchplate (4).

Unscrew and remove the four hexagon headed screws (1) with spring washers and
detach the catch housing (2).

Ensure the end of the elongated hook (12) is disengaged from the catch plate and lift
the plate away from the nosepiece being careful not to bend or damage the attached
leaf spring. Remove and discard both joints (3) and (5) either side of the catch plate.
Remove the trip lever stop screw (6) and spring washer, withdraw the trip lever shaft (11)
from the nosepiece complete with lever and return spring (23). Detach the return spring
and rubber ‘O’ ring (10) from the recess in the shaft.

Referring to figure 10, the pawl pin (2) is provided with an internal thread at its upper end
to enable the pin to be removed with the extractor (1), tool Part No. ST136.

Screw the extractor tool (1) into the tapped hole in the end of the pawl pin and while
holding the slotted end of the tool with a screwdriver, tighten down the nut in order to
extract the pin. It is recommended that once the pin is removed from the nosepiece
assembly, the extractor tool is left attached to the pin until it is refitted.

page 11
Fig.10 Removing the pawl pin and spring loaded plunger assembly from the nosepiece

Key to Numbers:-

1. Extractor tool Part No. ST136

2. Pawl pin
3. Top link
4. Elongated hook
5. Plunger sleeve and spring
6. Link plunger
7. Link pin
8. Pawl

Lift out the spring loaded plunger assembly, as shown in figure 10, complete with hook (4)
and pawl (8).

Press out the link pin (7), which is a press fit in the wide limb of the pawl (8), towards the
thin limb of the pawl and separate the link plunger (6) and hook from the pawl. Unscrew
the top link (3) and remove the spring and plunger (6) from inside the plunger sleeve (5).

page 12
COMPONENT INSPECTION AND RENEWAL
Clean the starter using a suitable proprietory fluid or paraffin as a cleansing agent and
examine all parts for damage or excessive wear.

Fig.11 Measuring spring settlement

SPRING CORE ASSEMBLY

Carefully examine the mainshaft. Pay particular attention to the two start thread, the
pinion thread, the thrust shoulder and the end track of the shaft. If either the mainshaft or
the ball but is chipped, cracked, badly fitted, damaged or worn it should be rejected
and a new one obtained.

If the ball seat insert in the spring sleeve is damaged or worn, see Fig.8, it must be
pressed out and a new ball seat insert fitted as follows:-

Position the spring sleeve, bevel gear teeth downwards, on the bed of a press. Using a
mandrel 31.75mm (11/4in) diameter x 152.5mm (6 in) long press out the insert. Remove
the mandrel from the press, reverse the spring sleeve and replace it in the press with the
bevel gear uppermost. Press in a new insert using the old insert, with ball trackway
uppermost, as a mandrel. Press until the new insert bottoms on the shoulder in the spring
sleeve.

The ratchet ring and ball cage should be inspected visually for damage or cracks and
rejected if damaged.

The complete pack of twenty-four disc springs must be renewed if:-

a) Their surfaces are badly pitted due to atmospheric corrosion.

b) Any disc is cracked or broken.

c) The distance from the end of the spring sleeve to the first disc spring exceeds 6.35mm
(0.25 in).

page 13
To check the spring settlement, stand the spring sleeve vertically on a flat surface, bevel
gear downwards, and stack the twenty four disc springs over the sleeve as shown in Fig.
11.

Using a depth gauge, as illustrated in figure 11, measure from the top of the inner edge
of the first disc spring to the end of the sleeve. If the spring settlement exceeds 6.35mm
(0.25 in) renew the complete pack of springs.

Referring to Figure 12, a number of starters were produced from Serial Number 371 UT
with an insert (3) to provide a shoulder inside the spring sleeve. If it is necessary to fit or
renew this insert, proceed as follows:-

To ensure that an insert, or machined shoulder, is not already present inside the sleeve
(2), check the internal depth of the sleeve measures 144.5mm (5.69 in), as given in
Dimension A.

Smear Araldite adhesive at the base of the sleeve inside the internal diameter to a depth
of 20mm (0.787in) as illustrated in Dimension B. Slide a new insert, tapered end first, into
the sleeve (2) pushing it firmly home against the shoulder. Allow sufficient time for the
Araldite to harden.

If it is necessary to fit a new ball nut or a new mainshaft, ensure that ball nut, mainshaft,
balls and ball cage function smoothly when assembled as a unit. If a new ball nut is
fitted, check that it slides freely in the slots of the spring sleeve. Similarly, if a new ratchet
ring or main pinion is to be fitted, check that the main pinion assembly functions smoothly
along the whole length of the five start thread when these components are assembled
together.

Fig. 12 Sectioned view of spring sleeve and insert

Key to letters and Numbers:-

A. Dimension 144.5mm
B. Dimension 20mm
1. Araldite adhesive
2. Spring sleeve, Part No. 96227 or 96006
3. Insert, Part No. 96401

END HOUSING (See Fig. 13)

Check bearing bushes and bearing sleeve for signs of wear or damage and discard
them where necessary.

If the bearing sleeve (1) is worn or damaged a complete new end housing assembly is
required.

page 14
Fig. 13 Fitting bearing bushes to end housing

Key to Numbers:-
1. Bearing sleeve
2. End housing
3. Spot face
4. Bearing bushes
5. Spot face

New bearing bushes (4) may be pressed into the end housing by the use of a fitting pin of
12.713mm (0.5005 in ) diameter. In the absence of a fitting pin, the winding shaft may be
used as a substitute.

Press each bush carefully into the casting until the end of the bush is level with the spot
face as shown in Fig. 13. After fitting the bushes check that the winding shaft runs freely
and smoothly in the bushes

NOSEPIECE (See Figs. 14, 15 and 16)

The inclined angle of 62 degrees to 69 degrees between the leaf spring and the
catchplate as illustrated in figure 14 should be checked to ensure it is within the specified
limits. If outside these limits the assembly must be rejected and a new one fitted.
Carefully examine the elongated hook, see figure 18, for any distortion or cracks inside
the hooked end. If any damage is apparent, a new hook must be fitted.
Fig. 14 Catchplate assembly

page 15
Carefully examine the elongated hook, see figure 18, for any distortion or cracks inside
the hooked end. If any damage is apparent, a new hook must be fitted.

Check and examine the pawl pin bushes in the nosepiece. Bushes showing signs of
excessive wear or damage must be removed and discarded. New bushes may be fitted
with the aid of fitting tool Part No. ST137 care being taken to ensure the dimensions of
32.95 to 33.15mm (1.297 to 1.305 in ) shown in Fig. 15 are correctly maintained. It is
important that the correct bushes are used as follows:-

Starter Serial No. Outer Bush Part No. Inner Bush Part No.
0 to 12805 96024 96372
12805 onwards 96024 96024

After fitting, check that the pawl is a free fit within the bushes.

Fig. 16 Fitting trip lever bush

Check the trip lever shaft bush for wear or damage and if required, fit a new bush
pressed in with a suitable fitting pin to the position as illustrated in figure 16.
When the bush is correctly fitted, insert 1 5/16 in. drill through the stop screw aperture and
drill through one side of the bush.

page 16
Tap out the hole, using a 24 UNF tap and remove any internal burrs from the bush. Check
that the trip lever shaft is a free running fit in the bush.

NEEDLE ROLLER BEARING (See Fig. 17)

Later versions of all types of spring starter have a ring staking groove machined in the
nosepiece to form a lip designed to prevent the needle roller bearing from working out
of its housing.

When removing or fitting a new bearing on these starters, it is imperative that the bearing
is NOT driven through the formed lip, but is removed or replaced in the direction shown in
Fig.17.

Fig. 17 Ring staked nosepiece

When servicing starters WITHOUT the ring staking groove, the needle roller bearing should
be removed and a retaining compound such as ‘Loctite Bearing Fit’ applied to the
mating surfaces of bearing and housing. Ensure that both surfaces are clean and dry
and that ‘Loctite is not allowed to contact the needle rollers.

Note: ‘Loctite’ should only be used if the replacement bearing is a light push fit in the
housing bore; it is NOT a remedy for an oversize bore.

RE-ASSEMBLY

GENERAL

All rubber ‘O’ rings, oil seals, sealing washers etc., must be discarded and new items
fitted when re-assembling the starter.

Recommended lubricants to be used on assembly are:-

Shell lubricant SB2628 and Rocol anti-scuffing paste.

page 17
The recommended sealing compound to be used, where applicable, on jointings and
face joints is Hylomar SQ32/M.

Where lubrication is mentioned in the assembly section, it refers exclusively to Shell

Lubricant SB2628.

Lightly lubricate all parts, during assembly, with the exception of the winding bevel gear
teeth, the bevel gear of the spring sleeve and the ball seat recess. These parts should be
lubricated at a later stage when the gear mesh and the main shaft end float have been
correctly adjusted by shimming.

Fig. 18 Exploded view of spring loaded plunger assembly

Key to Numbers:-
1. Top link
2. Spring
3. Elongated hook
4. Link pin
5. Pawl
6. Plunger sleeve
7. Link plunger

page 18
Key to Numbers:-
1. Nosepiece
2. Pawl
3. Pawl pin
4. Extractor tool, Part No. ST136

Fig. 19 Fitting the pawl pin

NOSEPIECE ASSEMBLY (See Figs. 18, 19, 20, 21 and 22)

Lubricate the needle roller bearing in the nosepiece.

Assemble the spring loaded plunger assembly, as shown in figure 18, by inserting the link
plunger (7), link end first into the open end of the plunger sleeve (6) and through the
small aperture at its opposite end. Insert the spring (2) into the plunger sleeve and screw
the top link (1) into the sleeve several turns.

Fit the link plunger (7) and elongated hook (3) between the limbs of the pawl (5) ensuring
that the hook is positioned on the side nearest the wider limb of the pawl. With all three in
alignment, press the pin (4) into the wider limb of the pawl. Lightly lubricate the working
surfaces of all parts.

Referring to figure 19, fit the spring loaded plunger assembly into the nosepiece (1)
aligning the pawl (2) between the pawl pin bushes. If the extractor tool (4), Part No.
ST136, has been removed from the pawl pin, or a new pin is being fitted, screw the
extractor tool into the tapped hole in the end of the pawl pin. (3).

Lower the pin in flush with the upper bush to retain the pawl and plunger assembly in the
nosepiece. Unscrew and remove the tool from the pawl pin. The pawl must be free to
rotate on the pin.

page 19
Fig. 20 Fitting the trip lever shaft

Key to Numbers:-
1. Trip lever
2. Return spring
3. Rubber ‘O’ ring
4. Shank- trip lever shaft
5. Stop screw and spring washer
6. Top link-plunger assembly

To fit the trip lever shaft, as illustrated in figure 20, assemble the return spring (2) to the
shaft engaging the hooked leg of the spring under the lever (1). Fit a new rubber ‘O’ ring
(3) into the groove provided in the trip lever shaft.

Lubricate the shank (4) and eccentric pin on the trip lever shaft. Insert the shaft into the
nosepiece, locating the offset pin through the top link (6) of the plunger assembly and
the leg of the spring into the casting.

Secure the shaft in position with the stop screw and spring washer (5), ensuring that the
end of the screw engages with the slot in the trip shaft, but do not fully tighten at this
stage. Rotate the trip lever to ensure that the spring returns the lever to the end of its slot.

The position of the pawl must now be checked using the pawl setting gauge, tool Part
No. ST123A, as shown in figure 21.

Insert the gauge (5) fully into the nosepiece so that the small diameter of the gauge is
located in the needle roller bearing.

With the trip lever (1) in the upright position, check that the hook is not binding in the
nosepiece casting and turn the gauge in both directions.

If the pawl (2) is correctly set, the ‘GO’ side of the gauge will clear the pawl and the ‘NO
GO’ side will foul, preventing further rotation of the gauge. If this condition is not
achieved, the pawl setting must be adjusted as follows:-

Remove the stop screw (6) from the nosepiece assembly and withdraw the trip lever
shaft. Using a pair of pliers, turn the top link (6) Fig. 20, on the plunger assembly in a
clockwise or anti-clockwise direction in half turn increments until the correct pawl setting
is obtained.

page 20
 Fig. 21 Nosepiece assembly shown with pawl setting gauge in position

Key to Numbers:-
1. Trip lever
2. Pawl
3. Nosepiece assembly
4. Pawl setting gauge, Tool Part No. ST123A
5. Gauge in situ
6. Stop screw and spring washer
Fig. 22 Exploded view of trip assembly

Key to Numbers:-
1. Socket headed screw and spring
washer
2. Catch housing
3. Joint
4. Catchplate
5. Joint
6. Stop screw and spring washer
7. Needle roller bearing
8. Nosepiece
9. Elongated hook
10. Trip lever
11. Rubber sealing bellows
12. Reset button

page 21
Refit the trip lever shaft and stop screw and re-check with the pawl setting gauge. Finally,
tighten the stop screw to a torque value of 10.9 to 13.6Nm (1.11 to 1.40 Kgf m or 8 to 10
Ibf ft).

To adjust the position of the trip lever on starters fitted with a cranked lever, slacken the
locknut and adjust the lever to the required position; re-tighten the locknut.

To assemble the trip assembly, see figure 22, apply sealing compound Hylomar SQ 32/M
to the contact faces of both joints (3) and (5), the nosepiece casting (8), catchplate (4)
and catch housing (2). Smear lubricant on the leaf spring, the slot in the catchplate and
the catch in the housing.

Fit the lower joint (5) in position on the nosepiece (7) followed by the catchplate (4).
Ensure that the leaf spring bears against the stem of the hook (9) and that the hook
protrudes through and locates freely within the slot in the catchplate. Fit the upper joint
(3) and the catch housing (2). The four screw holes are positioned such that the catch
housing cannot be fitted the wrong way round. Secure the housing with the four screws
and spring washers and tighten the screws to a torque value of 4.07 to 5.42Nm (0.41 to
0.55 Kgf m or 3 to 4 Ibf ft).

On marine type starters, or those which are used in particularly damp conditions, a
rubber sealing bellows (11) is fitted over the reset button (12). Smear with grease the
inside of the bellows and push the bellows, narrow opening first, over the reset button.
When fitted, the bellows should seal the catch housing without hindering the operation
of the reset button.

To test the operation of the reset trip mechanism, rotate the trip lever (10) through its full
90 degrees travel and check that the hook (9) engages in the slot of the catchplate (4)
and remains there when the trip lever is released. Pressing the reset button should
disengage the hook from the catchplate and permit the pawl to drop.

SPRING CORE ASSEMBLY (See Figs. 23, 24, 25 and 26)

Invert the spring sleeve (3) Fig.23, so that the bevel wheel is uppermost and fit a new
rubber ‘O’ ring (2) into the internal groove in the ball seat (1), which will be in situ in the
spring sleeve.

Lightly smear the ground mating faces and bore of each spring disc (4) and the slots and
outer surface of the spring sleeve with Rocol anti-scuffing paste.
Fig. 23 Exploded view of sleeve and spring discs

Key to Numbers:-
1. Ball seat
2. Rubber ‘O’ ring
3. Spring sleeve
4. Spring discs

page 22
Fig. 24 Assembled position for coloured spring discs

Stand the spring sleeve upright with the bevel wheel downwards on to a work bench, as
shown in figure 24, and assemble the first six pairs of UNPAINTED discs on the spring
sleeve. Place the two GREEN discs into position on the sleeve followed by five more
UMPAINTED discs. Finally, place one WHITE disc and four RED discs on the spring stack.

Numbering the colored discs from the top of the assembled stack would be:- RED,
Numbers 1,2,3 & 4; WHITE, Number 5; GREEN, Numbers 11 and 12.

Note; If new discs are to be fitted, degrease the periphery’s of seven of the discs and
paint them with the previously mentioned colours so that they may serve as indicator
springs.

Referring to figure 25, using Shell lubricant SB 2628, smear the entire length of the
mainshaft (3) with lubricant and more liberally, the bearing surfaces and screw threads.

Lubricate all internal and external surfaces including the holes for the steel balls on the
ball cage (4), also the internal thread and external surface of the ball nut (5).

Slide the ball cage (4), flange end first, onto the mainshaft and fit the sixteen 7.9mm
(5/16) diameter balls (1) into the holes in the steel ball cage.

Screw the ball nut (5), flange end first, onto the balls in the cage (4) until the nut and
cage abut the collar on the mainshaft. Check that both nut and cage move freely on
the screw threads.

Smear Rocol anti-scuffing paste on the inside diameter of the ball nut ring (6) and slide
the ring over the nut to locate against the four lugs.

Position the mainshaft assembly over the spring discs and lower the shaft with the plain
end of the ball nut (5) towards the sleeve and engage the lugs on the ball nut with the
longitudinal slots in the sleeve. Push the shaft through the rubber ‘O’ ring in the ball seat
insert until the ball nut ring (6) abuts the top spring disc.

Using the special press (1), tool Part No. ST138, as shown in figure 26, hold the press in an
upright position and clamp the legs of the press between the jaws of a vice.

page 23
Referring to figure 25, using Shell lubricant SB 2628, smear the entire length of the
mainshaft (3) with lubricant and more liberally, the bearing surfaces and screw threads.
Fig. 25 Exploded view of mainshaft assembly LuKey to Numbers:-

1. Sixteen 7.9mm diameter steel balls

2. Ten 7.9mm diameter steel balls
3. Mainshaft
4. Ball cage
5. Ball nut
6. Ball nut ring

Lubricate all internal and external surfaces including the holes for the steel balls on the
ball cage (4), also the internal thread and external surface of the ball nut (5).

Slide the ball cage (4), flange end first, onto the mainshaft and fit the sixteen 7.9mm
(5/16) diameter balls (1) into the holes in the steel ball cage.

Screw the ball nut (5), flange end first, onto the balls in the cage (4) until the nut and
cage abut the collar on the mainshaft. Check that both nut and cage move freely on
the screw threads.

Smear Rocol anti-scuffing paste on the inside diameter of the ball nut ring (6) and slide
the ring over the nut to locate against the four lugs.

Position the mainshaft assembly over the spring discs and lower the shaft with the plain
end of the ball nut (5) towards the sleeve and engage the lugs on the ball nut with the
longitudinal slots in the sleeve. Push the shaft through the rubber ‘O’ ring in the ball seat
insert until the ball nut ring (6) abuts the top spring disc.

Using the special press (1), tool Part No. ST138, as shown in figure 26, hold the press in an
upright position and clamp the legs of the press between the jaws of a vice.

page 24
Fig.26 Method of compressing the spring core assembly

Key to Numbers:- 1.Special press, tool Part No. ST138 3. Spring discs 5. Ten 7.9mm steel balls diameter
2.Bridge piece, tool Part No. ST122 4. Spacer, tool Part No. ST121

Slide the spacer (4), tool Part No. ST121, over the pinion end of the mainshaft and place
the assembly bevel gear uppermost in the press as shown in figure 26. Fit the bridge
piece (2), tool Part No. ST122, into the recess in the bevel gear and clamp the top part of
the press with the two locknuts. Screw down the press until the main spring discs (3) are
depressed approximately 9.5mm (3/8 in ).

Using tweezers, distribute the ten 7.9mm (5/16 in ) diameter steel balls (5) evenly around
the mainshaft in the undercut portion between the end track and the ball seat insert.

Slowly release the pressure, ensuring that the steel balls are correctly positioned and
evenly distributed around the mainshaft and that none are trapped. Before releasing all
pressure, tap the spring discs smartly with a hide mallet to ensure that the springs are
correctly settled.

Completely release the remaining pressure, again checking that the steel balls are
evenly distributed around the ball track and remove the spring core assembly from the
press.

PINION ASSEMBLY (See Fig. 27)

Smear the internal bore of the main pinion (2) or (10) with lubricant, also the external
surface of the pinion up to the gear teeth and the holes for the steel balls.

Ensure that the sharp edge on the bore of the circlip (5) faces towards the mainshaft
collar and slide the circlip on to the shaft

Lubricate the surface of the ratchet ring (6) and install the ring, with its chamfered edges
outwards, over the mainshaft.

On the short nose starters, fit the spring retainer (9) over the shank of the pinion (10)
followed by the return spring (8), large coil first and the spacing ring (7). Note a support
bearing (1) is fitted to the pinion on the long nose starter in place of the spring retainer
(9).

page 25
Fig. 27 Exploded view of pinion assemblies showing differences between long and short nose starters, marine application and oil sealed types

Key to Numbers:-
1. Support bearing }__Long nose starter
2. Long pinion }
3. Spring core assembly
4. Mainshaft
5. Circlip
6. Ratchet ring
7. Spacing ring
8. Return spring
9. Spring retainer }__Short nose starter
10. Short pinion }
11. Thrust washer
12. Disc spring
13. Five 7mm diameter steel balls
14. Inner rubber ‘O’ ring }
15. Outer rubber ‘O’ ring }__Marine applications and oil sealed
16. Seal housing-short nose starter }
17. Support bearing-long nose starter }

Note: On oil sealed starters or those used for marine applications, a seal housing (16) is
fitted to the short pinion (10). A support bearing (17) is fitted to a starter with a long pinion
(2). Fit new inner and outer rubber ‘O’ rings (14) and (15) and slide the seal housing, or
support bearing, small radius first over the shank of the pinion.

Slide the pinion assembly into position on the mainshaft so that the five 7mm diameter
steel balls (13) can be inserted in the holes provided in the pinion and also engage in the
five start thread.

Position the ratchet ring (6) over the steel balls and secure the ratchet to the pinion by
the circlip (5). Check that the pinion assembly moves freely up and down the five start
main thread.

END HOUSING ASSEMBLY (See Fig. 28)

Using the assembly tool, Part No. ST.148, grip the tool in an upright position between the
jaws of a vice and insert the hexagon end of the winding shaft (7) or (30) into the
assembly tool.

Smear the shaft and all parts of the winding mechanism with lubricant and assemble
them onto the shaft in the following sequence:

page 26
Fit one friction disc (19), over the threaded end of the winding shaft followed by the
ratchet disc (6). The ratchet disc, which rotates in a clockwise direction, must be fitted so
that the teeth on the ratchet faces in the direction opposite to rotation.

Fit the second friction disc (19), after the ratchet, screw the winding adaptor (20) onto
the shaft and secure with the retaining screw (22). Tighten the screw to a torque value of
9.5 to 12.2 Nm (0.97 to 1.24 Kgf m or 7 to 9 Ibf ft).

When assembled, check the ratchet disc for freedom of movement by unscrewing the
winding adaptor back against the retaining screw (22); the ratchet disc (6) should be
free to rotate.

Remove the winding shaft from the assembly tool.

Smear with Rocol anti-scuffing paste the side bearing surface of the winding adaptor
(20). It is important to ensure that no paste gets on the friction face between the adaptor
and friction disc (19).

Apply sealing compound Hylomar SQ 32/M to the flange of the plastic plug (23) and
press the plug into the end of the winding adaptor.

Lubricate the following parts of the end housing (11), the winding shaft bushes (12) and
(18), bearing sleeve on the end of the housing boss and the top plate studs.

On starters of clockwise rotation, see ‘A’ Fig.28, position the thrust washer (8) into the recess of
the housing and slide the winding shaft (7) into the housing. Fit the
bevel pinion (16) onto the hexagon on the shaft and secure the pinion and shaft with a
new circlip (17). Check, when fitted, that the winding shaft rotates freely.

Fig. 28 Exploded view of end housing showing differences between clockwise and anti-clockwise winding shaft assemblies

page 27
Key to letters and Numbers:-
A. Clockwise rotation
B. Anti-clockwise rotation
1. Locknut 7. Winding shaft 13. Joint 19. Friction discs 25. Thrust washer
2. Tab washer 8. Thrust washer 14. Cover plate 20. Winding adaptor 26. Bushes-winding shaft
3. Top plate 9. Allen cap screw and spring washer15. Screw and spring washer 21. Rubber ‘O’ rings 27. Distance piece
4. Pawl spring 10. Locking tab and lead seal 16. Bevel pinion 22. Retaining screw 28. Bevel pinion
5. Pawl 11. End housing 17. Circlip 23. Plastic plug 29. Distance collar
6. Ratchet disc 12. Bush-winding shaft 18. Bush-winding shaft 24. Retaining clip 30. Winding shaft

page 28
On starters of anti-clockwise rotation, see ‘B’ Fig.28, slide the distance collar (29) , bevel
pinion (28) and distance piece (27) into position on the shaft and insert the shaft into the
housing. Fit the thrust washer (25) and retaining clip (24) to secure the shaft. Check when
fitted, that the winding shaft rotates freely.

To adjust the Bevel Gear Mesh

Using a block of wood with a shallow ‘V’ cut shaped to suit the bevelled outer face of
the end housing (5), as illustrated in Fig.29, place the end housing with its register
uppermost on the block of wood.
Fig. 29 Method of shimming the bevel gears

Key to Numbers:-
1. Spring core assembly
2. Shim-bevel gear
3. Bearing sleeve
4. Bevel pinion
5. End housing
6. Bevel wheel

Wipe the teeth of the pinion gear (4) with ‘engineers blue’ and place the thickest bevel
gear shim (2) on top of the bearing sleeve (3). Shims are supplied in increments of 0.127
to 0.508mm (0.005 to 0.020 in).

Lower the spring core assembly (1) onto the end housing to mesh the teeth of the bevel
wheel (6) and pinion together.

Key to Numbers:-
1. Contact pattern 2. Bevel wheel
Fig.30 Area of mesh pattern

Oscillate the spring core several times about its axis and visually check the backlash
between the gears. If correct, the backlash should be 0.10 to 0.20mm (0.004 to 0.008 in)
The contact pattern on the gear teeth should be centrally disposed 40% to 60% over the
face width, as illustrated in Fig.30.

page 29
When the correct shim thickness has been established, keep the shims with the end
housing ready for final assembly.

page 30
END HOUSING ASSEMBLY - Continued.

Note: It is vital to the operation of the starter that the ratchet pawls (3) and (4) are fitted
the correct way round and the spring legs (7) are positioned as illustrated in Fig.31.

Lubricate and fit the two ratchet pawls onto the studs (2) and (5). Fit the springs (1) and
(6) so that one leg hooks over the pawl and pulls it into engagement with the ratchet
and the other leg presses against the winding housing.

To test, rotate the winding adaptor clockwise and observe that the pawls click round on
the ratchet disc (8). Rotate the adaptor anti-clockwise and observe that the pawls hold
the ratchet allowing the winding adaptor to screw back and release the pressure on the
friction disc. Re-check by turning the adaptor clockwise and observe that the ratchet
functions correctly.

Fig.31 Position of ratchet pawls and spring leg

Key to Numbers:-
1. Spring 5. Stud 8. Ratchet disc
2. Stud 6. Spring
3. & 4. Ratchet pawl 7. Spring legs
Referring to figure 32, smear the bore and ‘O’ seal groove (6) in the top plate (3) with
Rocol anti-scuffing paste and insert two new rubber ‘O’ rings (7) into the groove.

Key to Numbers:-
1. Nut 4. Winding adaptor 7. Rubber ‘O’ rings
2. Tab washer 5.End housing
3. Top plate 6. ‘O’ seal grooves

page 31
Apply sealing compound Hylomar SQ32/M to the joint face of the top plate and fit the
plate over the winding adaptor and studs. Ensure that the contour of the plate matches
the contour of the end housing.

Position two new tab washers (2) over the studs and locate them in the two small holes in
the top plate. Fit the two nuts (1) and tighten them to a torque value of 8.13 to 10.85 Nm
(0.83 to 1.11 Kgf m or 6 to 8 Ibf ft). Lock all tabs on completion. On earlier type starters,
spring washers are fitted; therefore the top plate must be renewed or drilled to suit and
tab washers fitted.

In order to fit the bevel gear cover plate (14), as illustrated in Fig.28, apply sealing
compound to both sides of the joint (13) and fit the joint and cover plate to the end of
the housing. Secure with the two screws and washers (15) and tighten to a torque value
of 4.07 to 5.42 Nm (0.41 to 0.55 Kgf m or 3 to 4 Ibf ft).

FITTING OF SUB - ASSEMBLIES

CARCASE AND NOSEPIECE (See Fig. 33)

Insert the nosepiece (2) into the stand (3), Part No. ST120, and assemble the carcase (1)
to the nosepiece keeping the scribe marks made during dismantling in alignment.

Fit the six socket head screws and spring washers (4) and with the extended Allen key,
tool Part No. ST129 and a 3/16 in. Whitworth spanner, tighten the screws in a diagonal
sequence to a torque value of 10.85 to 13.6 Nm (1.11 to 1.4 Kgf m or 8 to 10 Ibf ft ).

Fig.33 Fitting the carcase to the nosepiece

Key to numbers:-
1. Carcase
2. Nosepiece
3. Stand, tool Part No. ST120
4. Socket head screw and spring washer

page 32
CARCASE AND SPRING CORE ASSEMBLY (See Fig.34)

Stand the spring core assembly upright with the bevel wheel downwards on a work
bench as shown in figure 34 and position the thrust washer (4) and nosepiece disc spring
(5) on the end of the mainshaft. Ensure that the chamfered side of the thrust washer
abuts the shoulder of the shaft and that the convex side of the disc spring abuts the
thrust washer.

Lift and invert the nosepiece and carcase and position the carcase over the spring core
assembly.

Note: On the SS391-1 spring starter, a flat has been machined on the main pinion support
bearing, see (1) Fig.27, to enable the bearing to pass under the pawl. When fitting the
carcase and the nospiece assembly, the carcase should be rotated until the pawl is
aligned with the flat on the bearing.

Operate the trip lever on the nosepiece assembly to fully engage the hook into the
catchplate recess so that the pawl is in the raised position. Keeping the lever in the
tripped position, the nosepiece and carcase can the be lowered over the mainshaft
assembly without fouling until the shaft journal enters the bush in the nosepiece.

Fig. 34 Fitting the nosepiece and carcase to the spring core assembly

Key to Numbers:-

1. Nosepiece and carcase

2. Trip lever
3. Spring core assembly
4. Thrust washer
5. Nosepiece disc spring

page 33
END HOUSING AND CARCASE (See Figs. 35, 36 and 37)

Fig. 35 Fitting the end housing

Key to Numbers:-
1. Cap screw and spring washer 4. Bevel gear shim
2. End housing 5. Bevel wheel
3. Carcase shim 6. Nospiece

Place one hand under the bevel wheel, lift and invert the complete assembly and
position the starter vertically on end with the nospiece downwards on the stand as shown
in figure 35.

Fit the bevel gear shim (4), previously selected during the adjustment of the bevel gear
mesh, into the recess in the bevel wheel (5). Place the thickest carcase shim (3) on the
spigot of the end housing (2) and offer up the end housing to the carcase engaging the
bevel pinion with the bevel gear. Two sizes of shims are supplied in thickness of 0.02 in
and 0.04 in (0.51 and 1.02mm) .

Fit the end housing temporarily and secure in position with two of the cap screws (1),
then slowly rotate the winding adaptor pushing it inwards.

Reverse the assembled starter, placing the end housing in the ‘V’ shaped wooden block
so that the nosepiece is uppermost.

Using a set of special feeler gauges, tool Part No. ST232 to ascertain the end float on the
mainshaft, insert the feeler blade(s) (3), as shown in figure 36, between the thrust washer
(7) and nosepiece disc spring (1). Push the blade in fully to engage the radius of the shaft
and check that the end float is within 0.05 to 0.25mm (0.002 to 0.010 in).

page 34
Fig. 36 Method of measuring mainshaft end float and pinion face to flange mounting distance

Key to Letter and Numbers:-

‘A’ See ‘Table of Pinion to Flange Dimensions’

1. Disc spring
2. Nosepiece
3. Blade - feeler gauge
4. Flange mounting
5. Mainshaft
6. Pinion face
7. Thrust washer

Check also the pinion to flange mounting dimension by measuring the distance between
the face of the pinion (6) and the flange (4). The dimension ‘A’ as shown in figure 36,
should correspond with the starter type number given in the ‘ Table of Pinion to Flange
Dimensions.’

Table of Pinion to Flange Dimensions.’

Starter Type No. Dimension ‘A’ Assembly Code Starter Type No. Dimension ‘A’ Assembly Code
SS10/1 24 - 25 mm B3 SS26/1 47 - 48 mm B3
SS11/1 20 - 21 mm A7 SS27/1 27 - 28 mm A1
SS12/1 47 - 48 mm B3 SS28/1 47 - 48 mm D5
SS13/1 28 - 29 mm A1 SS29/1 20 - 21 mm D5
SS14/1 26 - 27 mm A1 SS32/1 20 - 21 mm B2
SS15/1 26 - 27 mm F7 SS34/1 47 - 48 mm D5
SS16/1 28 - 29 mm E5 SS39/1 47 - 48 mm D5
SS17/1 47 - 48 mm A1 SS40/1 20 - 21 mm B2
SS18/1 20 - 21 mm B3 SS41/1 20 - 21 mm D5
SS19/1 25 - 26 mm D5 SR12 47 - 48 mm C5
SS20/1 25 - 26 mm E5 SR13 28 -29 mm D6
SS22/1 28 - 29 mm A1 SR14 26 -27 mm C6
SS23/1 28 - 29 mm C3 SR17 47 - 48 mm C4
SS24/1 47 - 48 mm E6 SR23 28 - 29 mm A7
SS25/1 28 - 29 mm B2 SR25 28 - 29 mm A1
SR34 47 - 48 mm A1

page 35
If these measurements prove incorrect, the mainshaft end float and the pinion to flange
dimension can be adjusted as follows:-

To increase the mainshaft end float, fit a thicker carcase shim (3) Fig.35 to the end
housing or reduce the thickness of the thrust washer (7) Fig.36 in the nosepiece.
Conversely, a thinner carcase shim or a thicker thrust washer will give a larger pinion face
to mounting flange measurement, dimension ‘A’, Fig.36 but will decrease the end float.
Adjust accordingly.

The carcase shims are supplied in two sizes 0.5 and 1.0mm thick and the thrust washers
from 2.4 to 3.4mm thick in 0.2mm increments.

To change the shim and thrust washers, invert the assembly and locate the nosepiece in
the stand, tool Part No. ST 120, as shown in figure 35. Remove the temporarily fitted end
housing and change the carcase shim. Lift the carcase and nosepiece away from the
end of the mainshaft and change the thrust washer. Re-assemble the starter and
recheck the mainshaft end float and the pinion to flange dimension.
Fig.37 Location of sealed cap screw and inset of locking tab and lead seal

Key to Numbers:-
1.Cap screw and spring washer
2.End housing
3.Sealed locking tab and cap screw
4.Locking tab
5.Lock wire
6.Lead seal
7.Cap screw and spring washer

Before final assembly of the end housing on the carcase, partially fill the ball seat cavity in the
end of the spring sleeve with approximately 21 grammes (3/4 oz) of Shell Lubricant SB2628 to
the level of the head of the mainshaft. Lubricate the bevel pinion, bevel gear and bevel gear
recess. Apply sealing compound, Hylomar SQ32/M to the joint faces of the carcase, end housing
and both sides of the carcase shim.

Referring to figure 37, assemble the end housing to the carcase in the correct position marked
prior to dismantling. Fit the locking tab (4) to one of the six cap screws and spring washers (1)
and fit the screws in the end housing with the locking tab in the position as illustrated.

Tighten each screw in logical sequence to a torque value of 10.9 to 13.6 Nm 91.11 to 1.40 Kgf m
or 8 to 10 Ibf ft) and bend the locking tab over the screw. Wire the ends of tab together and
secure with the lead seal (6).

page 36
 TESTING

Note: The starter must not be wound and tripped without a load applied to the brakes.
Disregard of this instruction may result in internal damage to the starter.

Testing the spring starter after overhaul can be performed on an ‘Octopus’ test stand which has
been modified as follows:-

Fit a needle control valve, a restrictor and a pressure gauge, scaled 0 to 70 Kgf cm squared (0 to
1000 Ibf in squared), in the test stand hydraulic circuit. The restrictor can be made by plugging
one of the pipe line fittings and then drilling through the obstruction with a No. 75 drill (0.021 in.
diameter).

This method of testing serves only to check the correct function of the mechanism after overhaul
and does not provide a means of checking the developed torque or work output.

Warning: Before testing, ensure that the starter is unwound and that the GREEN painted
spring discs are visible through the carcase window.

1. Mount the starter on the test stand using a suitable adaptor plate; the clearance between
the pinion face and gear ring face should be 3.18mm (1/8 in).
2. Apply a brake pressure of approximately 5.6 to 7.0 Kgf cm squared (80 to 100 Ibf in
squared) and close the needle valve.
3. Press the reset button. Rotate the winding handle two revolutions only to engage the
starter pinion with the brake gear.
4. Open the needle valve to release the pressure.
5. Move the trip lever to the ‘Trip’ position. Rotate the winding handle and check for smooth
action.
6. Re-apply a brake pressure of 5.6 to 7.0 Kgf cm squared (80 to 100 Ibf in squared) and
close the needle valve.
7. Press the reset button and rotate the winding handle three revolutions.
8. Trip the starter to settle the internal components.
9. Press the reset button, then fully wind the starter.
10. Check the unwinding action by reversing the rotation of the winding handle for one
revolution, then re-wind the starter.
11. Increase the brake pressure to 13.3 to 14.7 Kgf cm squared (190 to 210 Ibf in squared)
and close the needle valve.
12. Trip the starter. The pinion should disengage from the gear ring after discharge.
13. Repeat tests 6,9,11 and 12.

page 37
GENERAL
The main pinion of the type SR range of spring starters rotates in an ANTI-CLOCKWISE
direction when viewed from the nose end of the starter.
The Description, Removal of Sub-Assemblies, Dismantling and Re-Assembly procedures
are substantially the same as for the type SS/1 spring starter and may be carried out with
reference to the detailed instructions in the preceding sections of this manual.
The majority of the components are identical for each starter type but except for the
winding shaft assembly the pawl pin and spring link assembly, all moving parts are
machined to the opposite hand.
The significant parts of the Type SR starter which differ are:-

NOSEPIECE ASSEMBLY
The rectangular block on the nosepiece casting which carries the trip lever shaft has
been moved 75 degrees around the casting.
The position of the main pawl is reversed so that it pivots to suit the new ratchet ring
rotation. The assembly position of the trip link mechanism is reversed accordingly. Offset
mounting holes, ensure that the catchplate assembly and the catch housing assembly
are fitted to face in the correct direction.
The trip lever is operated in the reverse direction to that of the standard Type SS/1 starter
and has its return spring wound to suit.

END HOUSING ASSEMBLY

The end housing casting is identical to that of the SS/1 starter but the winding shaft
bushes have a smaller bore (10.525mm) and each fits flush with a spot face in the
casting. A fitting pin of 9.5mm (3/8 in) diameter should be used if worn bushes are being
renewed.
The bevel pinion is reversed and is mounted near the centre of the winding shaft. The
winding adaptor is rotated in the same (clockwise) direction as for the SS/1 starter but
due to its new position on the winding shaft the bevel pinion reverses the direction of
rotation of the spring sleeve.

END HOUSING AND WINDING SHAFT

A distance piece and a flagged distance collar locate the bevel pinion relative to the
end housing casting and the machined flange on the winding shaft, respectively.
The assembly of the friction disc, ratchet disc, top plate, winding adaptor and retaining
screw is the same for both starter types.

WINDING SHAFT END FLOAT ADJUSTMENT

The winding shaft is held in position by an ‘E’ clip which bears against a thrust washer. This
thrust washer is available in graduated thicknesses from 2.6mm to 3.2mm (0.102 to 0.123
in) in steps of 0.2mm (0.008 in). Select the thickness of washer to give a winding shaft end
float of 0.05mm to 0.25mm (0.002 to 0.0101 in).

OVERHAUL OF ‘SR’ END HOUSING ASSEMBLY

The procedure is basically the same as for Type SS/1 starters except that the two
additional items, distance piece and flanged distance collar must also be removed from
the winding shaft.
Place winding shaft assembly tool, Part No. ST148, in the vice and use it to dismantle the
winding adaptor and friction disc assembly.

page 38
 LIST OF TORQUE VALUES
The torque values are correct at the time of printing. Any variations made necessary by
modifications or changes in design will be published in the relevant Service Instruction
Notes and the latest information must be followed.

ITEM Nm TORQUE Ibf in REMARKS

Kgf m
NOSEPIECE ASSEMBLY
Trip lever shaft stop screw 10.9 to 13.6 1.11 to 1.40 8 to 10 See Fig.20

Catch housing securing screws 4.1 to 5.4 0.41 to 0.55 3 to 4 See Fig.22

END HOUSING ASSEMBLY

Winding adaptor retaining screw 10.9 to 13.6 1.11 to 1.40 8 to 10 See Fig.28

Top plate securing nuts 8.1 to 10.9 0.83 to 1.11 6 to 8 See Fig.32

Cover plate securing screws 4.1 to 5.4 0.41 to 0.55 3 to 4 See Fig.28

CARCASE AND NOSEPIECE

Socket head screws 10.9 to 13.6 1.11 to 1.40 8 to 10 See Fig.33

END HOUSING AND CARCASE

Cap screws 10.9 to 13.6 1.11 to 1.40 8 to 10 See Fig.37

SPECIAL TOOLS
Description Part No.

DISMANTLING TOOL for Winding shaft ST148

STAND for Nosepiece ST120

EXTENSION KEY for Carcase/nosepiece screws ST129

PRESS TOOL for Spring core assembly ST138

SPACER TOOL for Spring core assembly ST121}

}used with ST138
BRIDGE PIECE TOOL for Spring core assembly ST122}

EXTRACTOR TOOL for Pawl pin ST136

FITTING TOOL for Pawl pin bushes ST137

SETTING GAUGE for Pawl ST123A

FEELER GAUGES for Mainshaft end float ST232

TWEEZERS for Steel balls; mainshaft end track

and ball seat insert 7244-277

page 39
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© IPU Group February 2009 2003/372