1. Product Overview
This manual provides essential information for the installation, operation, and maintenance of your new DB Electrical Starter. This unit is designed as a direct replacement for specific Daewoo Osgr 24 Volt applications, featuring an 11-tooth pinion and a 4.5 KW output.
The starter motor is a critical component in your vehicle's electrical system, responsible for rotating the engine to initiate the combustion process. Proper installation and adherence to safety guidelines are paramount for optimal performance and longevity.
Figure 1: Front angled view of the DB Electrical Starter, showing the main body, solenoid, and pinion gear.
2. Safety Information
Always prioritize safety when working with automotive electrical components. Failure to follow these guidelines may result in serious injury or damage to the vehicle.
- Disconnect Battery: Before beginning any work, always disconnect the vehicle's negative (-) battery terminal to prevent accidental electrical shorts or shocks.
- Wear Protective Gear: Always wear appropriate personal protective equipment, including safety glasses and gloves.
- Vehicle Stability: Ensure the vehicle is securely supported on a level surface using jack stands if lifting is required. Do not rely solely on a jack.
- Hot Surfaces: Engine components can be extremely hot. Allow the engine to cool down before working on the starter.
- Professional Installation: If you are not confident in your mechanical abilities, it is highly recommended to seek professional installation from a qualified technician.
- Correct Part: Verify that this starter is the correct replacement part for your specific vehicle application before installation.
3. Setup and Installation
The following steps outline a general procedure for replacing an automotive starter. Specific vehicle models may have variations. Refer to your vehicle's service manual for detailed instructions.
- Prepare Vehicle: Park the vehicle on a level surface, engage the parking brake, and ensure the engine is cool.
- Disconnect Battery: Disconnect the negative (-) battery cable, followed by the positive (+) battery cable.
- Locate Starter: Identify the location of the existing starter motor. It is typically mounted on the engine block near the transmission.
- Disconnect Wiring: Carefully disconnect all electrical connections from the old starter, including the main battery cable and the solenoid wire. Note their positions for reassembly.
- Remove Mounting Bolts: Loosen and remove the mounting bolts that secure the starter to the engine or transmission housing. Support the starter as bolts are removed to prevent it from falling.
- Remove Old Starter: Carefully maneuver and remove the old starter from its mounting position.
- Install New Starter: Position the new DB Electrical starter in place. Ensure the pinion gear aligns correctly with the flywheel. Install the mounting bolts and tighten them to the manufacturer's specified torque.
- Reconnect Wiring: Reconnect all electrical wires to the new starter, ensuring secure and clean connections. Pay attention to the correct terminals for the battery cable and solenoid wire.
- Reconnect Battery: Reconnect the positive (+) battery cable first, then the negative (-) battery cable.
- Test Operation: Attempt to start the vehicle. Listen for proper starter engagement and engine cranking. Check for any unusual noises or issues.
Figure 2: Rear view of the starter, highlighting the electrical connection points for proper wiring during installation.
4. Operating Instructions
The DB Electrical Starter operates automatically when the ignition key is turned to the 'START' position. Upon receiving an electrical signal from the ignition switch, the starter solenoid engages the starter motor. The motor then rotates the engine's flywheel, initiating the engine's combustion cycle.
- Ensure the vehicle's transmission is in 'Park' (P) for automatic transmissions or 'Neutral' (N) for manual transmissions before attempting to start.
- Turn the ignition key to the 'START' position and hold it until the engine begins to run, then release the key. Avoid prolonged cranking to prevent overheating the starter.
- If the engine does not start after a few seconds, release the key, wait approximately 10-15 seconds, and try again.
5. Maintenance
The DB Electrical Starter is designed for durability and requires minimal routine maintenance. However, periodic inspection can help ensure its long-term reliability.
- Inspect Connections: Periodically check all electrical connections to the starter for tightness and corrosion. Loose or corroded connections can impede current flow and affect performance.
- Clean Terminals: If corrosion is present on the battery terminals or starter connections, clean them thoroughly using a wire brush and a battery terminal cleaner.
- Listen for Unusual Noises: Pay attention to any grinding, whining, or clicking noises during engine start-up, which could indicate wear or a developing issue.
- Battery Health: Ensure your vehicle's battery is in good condition and fully charged, as a weak battery can put excessive strain on the starter.
6. Troubleshooting
If you experience issues with your starter, consult the following common troubleshooting steps. For complex problems, professional diagnosis is recommended.
| Symptom | Possible Cause | Solution |
|---|---|---|
| Starter clicks but engine does not crank | Weak or dead battery; Loose or corroded battery cables/connections; Faulty starter solenoid. | Charge or replace battery; Clean and tighten battery and starter connections; Test or replace solenoid. |
| Starter spins but engine does not crank | Faulty starter drive (bendix) gear; Damaged flywheel teeth. | Replace starter; Inspect flywheel for damage. |
| No response from starter when key is turned | Dead battery; Faulty ignition switch; Open circuit in starter wiring; Faulty starter motor. | Check battery charge; Test ignition switch; Inspect wiring for breaks or shorts; Test or replace starter motor. |
| Grinding noise during start-up | Misaligned starter; Worn starter drive gear; Damaged flywheel teeth. | Inspect starter mounting; Replace starter; Inspect flywheel. |
7. Specifications
Detailed technical specifications for the DB Electrical Starter, Model 410-58101.
| Specification | Value |
|---|---|
| Unit Type | Starter |
| Voltage | 24 Volts |
| Rotation | CW (Clockwise) |
| Teeth | 11 |
| KW | 4.5 KW |
| Gear OD | 1.579in / 40.1mm |
| Mounting Ear Holes | 13mm Unthreaded |
| Pinion Measurement (from flange, at rest) | 40mm |
| Starter Type | OSGR (Offset Gear Reduction) |
| Manufacturer | DB Electrical |
| Model Number | 410-58101 |
| UPC | 711811736179 |
| Item Weight | 18.8 pounds |
| Product Dimensions (L x W x H) | 15.5 x 10.1 x 7.8 inches |
| OEM Part Numbers | 017076, 65.26201-7076, 65.26201-7077B, 19982 |
Figure 3: Front view of the starter, clearly showing the 11-tooth pinion gear.
8. Warranty and Support
DB Electrical stands behind the quality of its products. This starter is covered by a 1-year warranty from the date of purchase.
- If the product does not perform as expected within one year of your order, DB Electrical will replace it.
- For warranty claims, technical assistance, or any product-related inquiries, please contact DB Electrical customer support.
- Please have your purchase details and product model number (410-58101) available when contacting support to expedite assistance.
