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D4 7U direct start conversion

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2 years 11 months ago #231624 by neil
Replied by neil on topic D4 7U direct start conversion
Zzzop, a 12v starter is plenty adequate, while a 24v will make it seem even easier. One of our old logging trucks contained a 903ci Cummins, which is considerably larger than the D4's engine and the 12v starter in that engine had no issues starting the engine in the dead of winter. It helps obviously that the 903 is direct injection and there are more cylinders to help get going but applying external heat like you're planning is the key to easy cold starts even on old clunkers like the D315. The block heater on my F350 makes starting it in winter just like it it was already running and warm. Just make sure you don't skimp on the battery cables. Use 00 cables, new clamps nicely soldered, clean and bright connections, and you won't have any issues.
I contacted a starter motor guy about building a 6v MT style starter for my 5U. He was quite interested in it and I really must get around to following up to see what size cabling I'd need. Existing cabling is 00 to the pony starter but the current draw on a 6V MT would be easily double that I'd say. I have a single 800CCA battery currently : ), and could easily fit two. My idea was to use the 6v starter for when I "accidentally" stalled it on the heap at the show in front of a bunch of girls, so as to save some face! I think it would have just enough to start the main when hot, and after getting it spinning over on no compression. All of this is just so's I don't have to replace the 6v generator. It's not the best technical solution obviously but it's one of those "I wonder if it would work" scenarios.

Cheers,
Neil

Pittsford, NY
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2 years 11 months ago #231625 by 8C 361
I would not worry about charging system. A relatively small solar panel will charge 12 or 24 volts no controller necessary. Keeping battery up while machine sleeps.
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2 years 11 months ago #231635 by Old Magnet
Might as well go 12v if it is more convenient for you. The early D315 heads will not accept glow plug chambers without machine work so there is no advantage there.
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2 years 11 months ago #231639 by Zzzopp
Old Magnet, thanks for the information!

I’ve read your page several times, it is definitely awesome information! MT 42 starter and 12t bendix just showed up. Starter shop is sourcing the Delco 198854 end housing now! Hopefully after some layout/drilling I might be able to start this D4 up Sunday!

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2 years 11 months ago #231649 by Zzzopp
Starter shop found this, it looks to be the correct one. 
Attachments:

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2 years 11 months ago #231773 by 1S1K
Replied by 1S1K on topic D4 7U direct start conversion
I built a jig out of aluminum to drill//tap the mounting holes as well as the 1/4" center hole for a hole saw. I used the dimensions from Old Magnets write ups and it worked great. I understand why most people go with 24 volt but I don't believe it's necessary. I used a 42MT with a single deep cycle optima, I made both cables from 2/0 welding cable as it will carry more current with less volt drop than standard wire. I can easily start it with just a little shot of either in 15F weather after sitting for several weeks. I don't have a charging system of any kind, I just put a battery charger on it when it starts cranking a little slower. I used it on a weekly basis or more often for over 4 months and only charged it once. The beauty of 12V is that I can jump it from my Diesel pickup if the battery were to get too low. If you use a 24V system there is no way to do that. Also, even though "wiring" would be cheaper the money saved would be more than burned up by buying 2 batteries instead of one, just my thoughts/experience. I would like to eventually put a pony back on just because, but for now I have a machine that is pretty quick/easy to get running. Good luck with your conversion. BTW make sure your starter pinion meshes with the ring gear on the flywheel correctly.
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2 years 11 months ago #231774 by 1S1K
Replied by 1S1K on topic D4 7U direct start conversion
One more thing, get a carbide tipped hole saw, bi metal didn't hold up at all
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2 years 11 months ago #231777 by Zzzopp
1s1k, what size hole did you drill? I was planning on 3-5/8”.

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2 years 11 months ago #231778 by Old Magnet
Is that drive end housing set up for o-ring seal or flat gasket. The correct lever housing will determine if you get the correct indexing.

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2 years 11 months ago #231782 by 1S1K
Replied by 1S1K on topic D4 7U direct start conversion
Yeah, I used a 3-5/8", at least that's what it measures, can't read the numbers anymore.

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