Intro and Changfa starters.

[dmparrish]

Hey. Just started on this list and wanted to show off the genset I built for our property off the coast of Belize in '07. It has a Weichai ZS1115 with belt driven 15kW ST generator head, original radiator remotely mounted with electric fan and a dis-mountable 5 gal (outboard) fuel tank for easy filling.

It has about 136 hours on it now, (As long as the AC isn't used, the solar/battery/inverter system takes care of most needs.) and has run fairly well with only minor oil leaks, and some rewelding. The legs that come the engine are far too light for the engine's strong vibration and one frame member broke. (NOT my welding on that one.)

When I bought it, I got just about all the spare parts possible, though the starter I got wasn't the correct one. Of course, the starter now has broken parts inside.

Does anyone know where to get a new starter or has it's mounting dimensions? I suspect the starter is a fairly common industrial or possibly even auto model. It's doubtful they'd design a new starter just for this application.

Thanks for any help.
David

[flywheel]

Look in the Parts Source section of the forum.  Kim will order one for you if he has none in stock. 

The legs on these engines ( the ones that always break ) are just for shipping.  Without the legs the oil pan will be resting on the floor. 

Nearly everyone who uses a belt drive system will remove the legs and mount their engine on wood or steel beams. 
                                                                                                                                                                              flywheel

[veggie]

That's a nice rig.
Just curious...the radiator has be removed and mounted high in the frame.
Did you set up the cooling system for thermsiphon(sp) circulation or did you add a circ pump?
It's hard to see in the picture but if it's a thermosiphon, there should be two lines from your adapter plate to the radiator base.
(HOT supply and COLD return)
Secondly, with the only radiator connections being at the bottom of the radiator, a proper thermosiphon circulation is hard to achieve.
Typically an inlet at the TOP of the rad is needed for thermosiphon action.

Not saying that yours doesn't work, just curious as to how it's set up.

cheers,
veggie

PS: That engine fully loaded will be rejecting approx. 38,000 btu/hr., so if your current setup is any less effective than the stock setup, you may see some serious overheating if/when you take the genset to it's full capability.
Again, it's hard to see the arrangement you have and it will be interesting to learn how you have set things up.

[rcavictim]

Nice set up.  I worry though that the vibration and shaking will destroy your starting battery where it is mounted.  Best get it off the machine entirely and set it on the floor next to the plant.  Don't ask me how I know.   

That starter looks just like the one and same mounting location as that on my Changfa ZS1115GM.  The way the unsupported rear end of it vibrates violently makes me think I'd better devise a reinforcement mount for it or expect it to fail early.

Welcome!

[flywheel]

Nice set up.  I worry though that the vibration and shaking will destroy your starting battery where it is mounted.  Best get it off the machine entirely and set it on the floor next to the plant.  Don't ask me how I know.   

That starter looks just like the one and same mounting location as that on my Changfa ZS1115GM.  The way the unsupported rear end of it vibrates violently makes me think I'd better devise a reinforcement mount for it or expect it to fail early.

Welcome!

Starter vibration,  some engines have small bolt with a jamb nut to prevent starter vibration.  After the starter is installed the bolt is backed out and puts pressure on the starter housing and the jamb nut locks the bolt in place.

The bolt is threaded into the rear access cover in this example which is on my Redstone engine.    This prevents the starter from vibrating. 

Some engines do not have enough room for a bolt and jamb nut.  In this case a wood wedge is driven between the starter housing and rear cover or block.

The bolt and jamb nut can be seen in the attached pix.
                                                                                        flywheel

[rcavictim]

Nice set up.  I worry though that the vibration and shaking will destroy your starting battery where it is mounted.  Best get it off the machine entirely and set it on the floor next to the plant.  Don't ask me how I know.   

That starter looks just like the one and same mounting location as that on my Changfa ZS1115GM.  The way the unsupported rear end of it vibrates violently makes me think I'd better devise a reinforcement mount for it or expect it to fail early.

Welcome!

Starter vibration,  some engines have small bolt with a jamb nut to prevent starter vibration.  After the starter is installed the bolt is backed out and puts pressure on the starter housing and the jamb nut locks the bolt in place.

The bolt is threaded into the rear access cover in this example which is on my Redstone engine.    This prevents the starter from vibrating. 

Some engines do not have enough room for a bolt and jamb nut.  In this case a wood wedge is driven between the starter housing and rear cover or block.

The bolt and jamb nut can be seen in the attached pix.
                                                                                        flywheel

Thanx for this!  Perhaps I'll give my genset a hard maple wedgie. 

[dmparrish]

> Veggie:

> Just curious...the radiator has be removed and mounted high in the frame.
> Did you set up the cooling system for thermsiphon(sp) circulation or did you add a circ pump?

It's thermosiphon with an electric fan, and so far, it has worked quite well. (Didn't trust a copper radiator of uncertain quality to the vibration on the engine.) Power is through a Trace/Xantrex SW4048, so maximum power draw is about 3kW charging batteries, plus two 5500BTU window units, a couple of fridges and a few compact fluorescent lights. (Water pump draws quite  bit of power, but short enough duration to not matter much on engine heat load.) Maybe 5-6kW total. If we can scrape up the funds, we'll finish the lower floor and add a parallel inverter. Maybe then the thermosiphon won't be enough.

> Rcavictim:

> Nice set up. I worry though that the vibration and shaking will destroy your starting battery where it is mounted.

The gen head and engine are mounted on a rubber mounted subframe to limit vibration to the radiator/battery/power panel/etc. (And the power plug would still vibrate loose.)

> That starter looks just like the one and same mounting location as that on my Changfa ZS1115GM.
> The way the unsupported rear end of it vibrates violently makes me think I'd better devise a reinforcement mount for it or expect it to fail early.

Too late.  That's the reason for the original post. I need a new starter, or at least some cross references or sources for same.

> Flywheel:

> Some engines do not have enough room for a bolt and jamb nut. In this case a wood wedge is driven between the starter housing and rear cover or block.

Not a bad idea. Thanks.


Oh, to see my Weichai's (Changfa) home, go to http://southkeep.com (I hate being envious of a Diesel engine!)

---
David

[rcavictim]

> Too late.  That's the reason for the original post. I need a new starter, or at least some cross references or sources for same.
---
David

David,

Quite the place you have there!  Have you disassembled the starter motor to see what is wrong?  What exactly got damaged from the vibration?

[dmparrish]

>  Have you disassembled the starter motor to see what is wrong?  What exactly got damaged from the vibration?

Our caretaker discovered the problem, and since I can only get down there two-three times a year, he can only call when on the mainland, and internet access is gone since the hurricane hit the University of Belize marine station just up island, finding out what's wrong isn't easy.

According to one of the other partners, Javon took apart the starter and 'Pieces fell out.' Fortunately, Javon is quite good with chewing gum and bailing wire. 

[rcavictim]

>  Have you disassembled the starter motor to see what is wrong?  What exactly got damaged from the vibration?

Our caretaker discovered the problem, and since I can only get down there two-three times a year, he can only call when on the mainland, and internet access is gone since the hurricane hit the University of Belize marine station just up island, finding out what's wrong isn't easy.

According to one of the other partners, Javon took apart the starter and 'Pieces fell out.' Fortunately, Javon is quite good with chewing gum and bailing wire. 

Having good people like that on the front lines is the best.  Worth a thousand university diplomas in the real world!