DaLin Disc Spring Starter Operation Manual

1. DaLin Disc Spring StarterOperation 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 For any print errors and outdated content, we will make corrections in time and update them in the latest version without prior notice.

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! Chongqing Starting Power Unit Co. Ltd

3. Table of Content Chongqing Starting Power Unit Co. Ltd

4. 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 Chongqing Starting Power Unit Co. Ltd

5. Kit Parts and Starter Storage • The kit parts in the starter shipping box includes pieces shown on the right table: • Starter Storage • Although the starter • has been anti-rusted, • for long time store, the • starter should be put in • the area with dry and • clean environment. • Don’t energize and • release the starter • when it is stored on a • bracket! 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. Chongqing Starting Power Unit Co. Ltd

6. Starter outside view A micro-lock switch is mounted here for Dual starter engines, see page 18 Chongqing Starting Power Unit Co. Ltd

7. Brief of the structure 18 17 16 2 1 19 15 14 A micro-lock switch is mounted here 3 20 4 5 6 8 10 11 12 9 7 13 Chongqing Starting Power Unit Co. Ltd

8. 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 1－Heavy Duty 2－HD Plus 3－Super HD 4 -- HD Plus 2 The suffix letter is for special requests raised by customers and changes Series Data plate Instruction plate 1－Clockwise, viewing toward front at flywheel end of the engine 2－Anti- clockwise, 2101 A Turning direction code Application number Trip lever reset direction Trip lever release direction Chongqing Starting Power Unit Co. Ltd

9. Installation - General 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. 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. Chongqing Starting Power Unit Co. Ltd

10. 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. Installation – Pre-check Starter mounting surface Ring gear 飞轮齿圈 A B Chongqing Starting Power Unit Co. Ltd

11. 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. Operation Instruction plate convexity ‘0－0’ mark Input adaptor Trip lever Always! ...... view starter from front to rear for sequence of ‘A,B,C…’ on the front cover and ‘1,2,3….’ on the rear cover Front cover Body Rear cover Chongqing Starting Power Unit Co. Ltd

12. Installation 4 – Winding angle 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. Chongqing Starting Power Unit Co. Ltd

13. Installation 5 – Rear cover and pinion Caution：while starter is installed on the engine, please ensure proper gear engagement to avoid parts breaking during operating. (please see page 10) 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 Chongqing Starting Power Unit Co. Ltd

14. 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. Groups and functions Trip lever Reset knob Installation flange The trip lever is at RESET position The trip lever is at TRIP position Chongqing Starting Power Unit Co. Ltd

15. Operation Please read < DL Starter Operation Instruction > carefully. Make sure the starter has been installed on engine properly. 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. Chongqing Starting Power Unit Co. Ltd

16. 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. Chongqing Starting Power Unit Co. Ltd

17. 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! Chongqing Starting Power Unit Co. Ltd

18. 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. Chongqing Starting Power Unit Co. Ltd

19. 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. Chongqing Starting Power Unit Co. Ltd

20. 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. 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. Chongqing Starting Power Unit Co. Ltd

21. DL Starter Specification Starter application data L Starter Size (mm) ΦB ΦA Chongqing Starting Power Unit Co. Ltd

22. 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

23. CHONGQING STARTING POWER UNIT CO., LTD. Part number：230517-05