DaLin Disc Spring Starter Operation Manual Chongqing Starting Power Unit Co. reserves the right to modify the parameters herein. For any print errors and

DaLin Disc Spring Starter Operation Manual

Chongqing Starting Power Unit Co. reserves the right to modify the parameters herein. For any print errors and outdated content, we will make corrections in time and update them in the latest version without prior notice.

Chongqing Starting Power Unit Co. Ltd 2

Caution

Proper installation is needed before winding and tripping

operation! Prohibit no-load energizing and releasing!

When starter is in non-working condition, always put the

trip lever in ‘Trip’ position to avoid damage of starter,

especially on twin starter engine.

Use right cranking handle to wind the starter and stop

winding once one or two red color spring occurs at the

viewing window!


Table of Content

• Modifications (Inside front cover) P1

• Caution P2

• Table of content P3

• Welcome/Contacting P4

• Kit parts P5

Starter Storage P5

• Starter outside view P6

• Brief of the structure P7

• Data & Instruction Plate P8

• Installation-general P9

Attention 1 P9

Turning direction P9

Installation space P9

To be a replacement P9

• Pre Check P10

• Winding handle direction and adjustment.

P11

• Winding angle code P12

• Rear cover & pinion P13

• Groups and functions P14

• Operation P15

• Other important operations P16

Unwinding P16

Slowly crank the engine P16

Cold starting P16

• Dual starter engines P17

micro-lock switch and wiring P18

• Different flywheel housings P19

Attention 3 P19

• Trouble Shooting & Warning P20

• Starter specification P21

DL starter size P21

- Warranty (inside back cover) P22

• Back cover


Welcome and Contacting

Thanks for your proper choice! DaLin (DL) Diesel engine starter serves with reliable performance. If you have

questions during installation and operation, please contact with us. The contacting information is as follow:

Chongqing Starting Power unit Co., Ltd.

Plant add ： Chenjiaqiao ， Shapingba ， Chongqing ， China Post Code ： 401331 Phone: +86-23-65660596 Fax: +86-23-65660726 Sales hotline: +86-139-8309-3170 Service hotline: +86-136-0833-1945

Company add ： B 10-14, Wangfujing Building, Shapingba, chongqing, China Post Code ： 400030 Phone: +86-23-65304592 Fax: +86-23-65304592

Company Web-site ： www.cqstart.com


Kit Parts and Starter Storage

The kit parts in the starter shipping box includes pieces shown on the right table:

Part and Description No.

Winding Handle （ For easy packing, The handle is disassembled into two parts. It can be assembled again. The torque value of M10 cap screw is 13-15Nm ）

1

《 Operation Manual 》 (PN230517) 1

《 Operation Instruction 》 (PN230530) 1

《 Starter View Window Color Instruction 》Sticker (PN230519) – on the body of the starter

1

Cardboard gauge for checking distance between front face of ring gear to starter mounting surface on the flywheel housing (PN230520)

1

Inspection/acceptable record (PN230521)

- It is stuck on the back of the cardboard

1

Starter Storage

• Although the starter has been anti-rusted, for long time store, the starter should be put in the area with dry andclean environment.

• Don’t energize and release the starter when it is stored on abracket!

Note: For packing purpose, the angle of the trip lever may not be proper for use. The angle can be adjusted. Torque value of lock nut is 12-14Nm.


Starter outside view

A micro-lock switch is mounted here for Dual starter engines, see page 18


Brief of the structure

12

3

4 5 6 7 8 9 10 11 12 13

14

1516171819

sn.

Description sn. Description sn. Description sn.

Description

1 Body 6 Spring bundle 11 Drive pinion 16 Reset knob

2 Input adaptor 7 Screw sleeve 12 Rear cover 17 Instruction plate

3 Front cover 8 Main shaft 13 Lock 18 Trip lever spring

4 Drive gear 9 Circlip 14 Lock screw 19 View window

5 Driven gear 10 Ratchet 15 Trip (release) lever 20 Data plate

20

A micro-lock switch is

mounted here


Data & Instruction Plate

The data plate is on the front cover and instruction plate on the rear cover;

Trade mark on the data plate; PN ： Assembly number, showing starter

Series, turning direction, angle code, etc ； SN ： Serial number for individual unit of

the starter.

Trade mark

Assy Number

Serial Number

Mounting holes

Trip lever reset direction Trip lever release direction

2101 A

1 － Heavy Duty2 － HD Plus3 － Super HD4 -- HD Plus 2

1 － Clockwise, viewing toward front at flywheel end of the engine

2 － Anti- clockwise,

Application number

Turning direction

code

Series

Data plate

Instruction plate

The suffix letter is for special

requests raised by customers and changes


Installation - General

It’s easy to install and operate DL starter, but you still need to read the operation manual carefully before working on it.

Turning direction ： the turning direction code is shown on the data plate. please see page 8

Installation space ： there should be enough space for starter installation and cranking

To replace original starter ：（ 1 ） Take the electric or air starter off from the engine and ensure if there is a spacer which may be used for DL starter ；（ 2 ） When taking the original starter off, please check if the electrical fuel shut-off valve is closed. Electric power could be provided directly from the battery, or open the valve manually. (3)The pinion tooth number may be different between DL starter and original starter, and the center line of the rear cover may be offset for suitable engagement of the gears and larger space for starter installation.

Attention 1 ： Don’t crank and release the starter before it has been properly installed on the engine! The inside parts will be damaged if the starter is energized and released without engine starting load. The warranty will be negated.


Installation – Pre-check

According to design, the gap between pinion and

flywheel ring gear (B-A, see illustration below) is

about 3-5mm. Please check the depth from

starter mounting surface to the ring gear front

face through starter installation hole using

cardboard gauge. When cardboard touches the

ring gear ， the green line should be at the

starter mounting surface. Or measure the gap

directly.

For check the engagement of the

gear, please make sure that the

tooth height engaged should be

larger than ½ full height of the gear

tooth.

The pinion can extend 19mm from

it’s rest position.

AB

Starter mounting surface

飞轮齿圈Ring gear


Installation – Winding angle

Torque value to install starter on the engine should meet the requirement of the engine

building specification.

While the starter is mounted on the engine ， the input adaptor position should be

comfortable for cranking the handle. If not, you can rebuild the assembly to change the

winding angle. Please see illustration on this page and the table on next page.

Before rebuild ， please put the trip lever at ‘trip’ position.

Front cover Rear coverBody

‘0 － 0’ mark Input adaptor Trip lever

Operation Instruction plate conve

xityAlways! ......

view starter from front to rear for sequence of ‘A,B,C…’ on the front cover and ‘1,2,3….’ on the rear cover


Installation 4 – Winding angle

Angl ecode

Angl eval ue °＋

Angl ecode

Angl eval ue - °

1A 0 1A 02B 8. 5 6G 8. 53C 17 5F 174D 26 4E 265E 34 3D 346F 43 2C 431G 51 1B 512A 60 6A 603B 69 5G 694C 77 4F 775D 86 3E 866E 94 2D 941F 103 1C 1032G 112 6B 1123A 120 5A 1204B 129 4G 1295C 137 3F 1376D 146 2E 1461E 154 1D 1542F 163 6C 1633G 171 5B 1714A 180 4A 180

The winding angle is defined the angle between input adaptor and operation instruction plate convexity.

To meet the variation of winding angle, different screw hole segment on front and rear cover provides the possibility to make adjustment ：（ See illustration on page 11)

－ A,B,C,D,E,F and G on the front cover sequenced clockwise (View from front to rear).

－ 1 ， 2 ， 3 ， 4 ， 5 and 6 on the rear cover sequenced clockwise. (View from front to rear too).

－ Angle code and angle value are shown on the right table.


Installation 5 – Rear cover and pinion

Pinion parameters (modulus ， pressure angle, etc. ） may be changed for different applications

Rear cover center line has two choices: concentric and offset

Concentric or offset spigot

Caution ： while starter is installed on the engine, please ensure proper gear engagement to avoid parts breaking during operating. (please see page 10)


Groups and functions

The functions of DL starter groups is that:

Input manual energy through

cranking group. The energy is stored

by energizing group. The releasing

group is starter control mechanism.

Pull reset knob to reset the trip lever

and ready to be energized. Push trip

lever toward trip direction to release

energy to start the engine. The first

two cranking turns is to move pinion

toward ring gear for gear

engagement. When engine is

rotating, the pinion moves backward

and gears will be disengaged

automatically by working of clutching

group.

Trip lever

Reset knob

The trip lever is at

RESET positionThe trip lever is at

TRIP position

Installation flange


Operation

1. If the starter is fitted on a engine with gearbox or other power output device, ensure that the gearbox is in the neutral position.

2. Check that fuel has reached the fuel pump and fuel valve (actuator) is in the 'ON(open)' position.

3. Adjust the throttle to between 1/2 and 3/4 full open. Some electronic speed control need to reset program to enlarge minimum fuel throttle opening.

4. If there is start fuel adjust on engine speed controller, it may be necessary to adjust the fuel knob to maximum position.

5. The trip lever (with the red ball) of the starter is normally at ‘TRIP’ position. Once engine starting is needed, pull the reset knob. The trip lever will immediately spring back to its RESET position.

6. Fit right cranking handle on input adaptor and wind the handle 2 turns slowly only in a clockwise direction for fully engagement of starter pinion with flywheel ring-gear.

7. Important suggestion: Before energize the starter, please refer to <Slowly crank the engine> on next page to crank the engine about 1-2 turns, especially for cold engine that didn’t run for a long time. Wind the handle in same direction until 1 or 2 red springs are visible through the view windows (See page 21 for number of turns).

8. To start your engine, push the trip lever toward ‘TRIP’ direction through 90 degrees. If the engine does not start, repeat the above steps.

Please read < DL Starter Operation Instruction > carefully. Make sure the starter has been installed on engine properly.


Other important operations

Unwinding

If fully winding is unexpected and it is necessary to de-energize the starter, 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 viewing windows. At this point the starter pinion will also retract to its rest position.

Slowly crank the engine

The DL Starter can be used to slowly crank an engine, for pre-cranking before engine cold starting or for the adjustment of valve lash, pump timing or equipment coupled to the engine. With the trip lever in the RESET position, slowly turn the winding handle clockwise about two turns. This will engage the pinion with the ring gear. Now trip the lever through 90 degrees. The reset knob will fall in and lock the trip lever in this position. The engine can now be turned with the winding handle without compressing the spring pack, and any adjustments, to the engine, may be made. Once slow cranking is completed you should pull the reset knob and either fully wind to start the engine (see Operation) or unwind to disengage the pinion (see Unwinding).

Cold Starting

When starting at ambient temperatures below 0℃, it is 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.


Dual starter engines

Where the engine has the facility to be operated using two starters (for example an electric starter and a DL starter), the DL starter must have its pinion disengaged from the engine flywheel when the electric starter is being used. It means that The trip lever must be in ‘TRIP’ position when using alternative starter. Please refer to the illustration on the right side.

Attention 2 ： Do not attempt to start the engine with an electric or other starter while the DL Starter is wound and engaged!

Micro-lock switch


On Daul starter engines, to avoid damage of the starter, the disc spring starter prepared micro-lock switch that’s mounted on the rear cover. Refer to page 6 and 7.

For wiring of the micro-lock switch, please refer to illustration on right side.


Engine with different flywheel housing

One model of engine may have two or more flywheel housing which are

designed for different starter application, so that the distance between

center of starter mounting hole and the center of engine crankshaft could

be changed for various starter (electric, pneumatic or hydraulic):

1. Please refer to page 13. The DL starter is flexible to meet

the requirement of application;

2. Please refer to page 10. The pre-check should be performed

carefully to avoid starter failure during operation.

Attention 3: When DL starter replaces an original starter, please ensure that the DL starter rear cover and pinion is designed for

this application, except starter capability.


Trouble shooting （ Refer to page 7）

DL Starter operation should be trouble free as long as it has been fitted correctly. On slowly turning the winding handle first two turns in a clockwise direction the input adaptor

should be rotated smoothly and causing the pinion move forward engaging with the flywheel ring gear. Further winding will cause the spring pack compressing and energizing as viewed through the viewing window on the body.

Fault Cause Action

Input adaptor could not be turned The bevel gear is broken and is locking the drive gear

Replace the bevel gear and check the drive gear for damage

Input adaptor turning is ‘stiff’ or not smooth

The lash between bevel gear and drive gear is too tight

Add or remove shim from between front cover bearing and drive gear

Input adaptor rotates but the spring core is not compressed and turned

The input shaft or the bevel gear is broken. Replace the bevel gear or input shaft

Input adaptor rotates but the pinion does not rotate and move forward

Ratchet is broken or circlip looses

Burring on shaft thread or over-rust

Change ratchet or circlip

Deburr or change the shaft

Spring core can be compressed, but discharges itself prematurely

The height of ratchet lock is incorrect

The lock or ratchet are worn

Adjust the height

Replace worn parts

Starter jams during spring core compression or fails on tripping

Worn shaft or screw sleeve causing the ball bearings to jam between them

Unwind the input adaptor until green color can be seen through view window, then disassemble.

IF starter still can’t be discharged. Please see the WARNING below.

WARNING: Do not attempt to dismantle a jammed starter as this is dangerous! Keep your fingers away from the pinion. Only lift the starter by trip lever with red ball. Contact your local expert to solve the problem.


DL Starter Specification

Φ AΦ B

L

Starter application data

Starter Size (mm)

STARTER

SERIESL A B

1100 288 117 130

2100 332 117 130

4100 368 117 130

3100 368 133 143

5100 / 5200 255 117 130

HD HDP HDP2 SHD MD

1100 2100 4100 3100 5100/5200

Mounting Flange SAE # on standard 1,2 & 3 1,2 & 3 1,2 & 3 1,2 & 3 1,2 & 3

1.7 & 6 2.1 & 6 2.5 & 6 0.8 & 6

1.4 & 8 1.7 & 8 2.0 & 8 1.0 & 4

Max. Pinion torque Nm 126 126 126 167 126

Max. Winding torque Nm 100 100 100 100 100

Weight kg 18 21 23 26 16

Turns to fully wind Turns 2+8 2+11 2+13 2+15 2+6

1.4 & 6

DL starter SeriesRotating clockwise

except 5200

Diesel Engine

Displacement

Liter(l)/Cylinder

& Max cyl. number


Warranty

Warranty period: One year(12 months) starting from the date shipping from our company. We can also implement warranty according to OEM’s agreement.

Warranty range: Any defect caused by starter assembly or part material and manufacturing. The starter should be properly installed and operated.

Rejection of warranty: - Failure caused by energizing and releasing before the starter properly

installed on the engine. - Failure caused by alternative starter working under the condition that

spring starter driving gear has engaged with ring gear of flywheel. - Defects cause by incorrect storage and shipment.

CHONGQING STARTING POWER UNIT CO., LTD.

Part number ： 230517-05

Documents

DaLin Disc Spring Starter Operation Manual Chongqing Starting Power Unit Co. reserves the right to modify the parameters herein. For any print errors and