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Type :
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starter
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Specification :
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24V 6.5KW
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Number of feet :
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10T
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Brand :
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nuojin
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Number :
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5348134 QDJ2717A
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Quality :
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Remanufacture
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Delivery time :
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10 day
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The installation of the 24V 6.5KW Cummins starter must follow the process of power-off preparation, cleaning and alignment, fastening, wiring connection, and test verification. Meanwhile, key details such as bolt torque and wiring interfaces should be strictly controlled. The specific installation method is as follows:
Prepare a torque wrench (calibrated to 25-30N·m), cleaning cloth, feeler gauge, thread locker, etc. Meanwhile, verify that the new starter model is compatible with the engine, check for no external damage, no deformation of the drive gear, and complete spare parts.
Disconnect the negative terminal of the storage battery to avoid short circuits during installation that may damage the starter or other electrical components. The storage battery matched with this Cummins starter model must meet the requirements of capacity ≥180Ah and CCA (Cold Cranking Amps) ≥1300A. It is advisable to check if the storage battery is fully charged.
Clean the mounting surface of the starter on the engine: use a cleaning cloth to remove oil stains, rust, and dust from the surface to ensure the mounting surface is flat and clean, preventing loosening or vibration noise after installation.
Align the gear end of the new starter with the engine flywheel ring gear, adjust the position to ensure the starter axis is parallel to the flywheel ring gear without deviation or skew, avoiding abnormal gear meshing later.
Fit the starter tightly to the mounting surface, align with the reserved mounting holes, and insert the fixing bolts (usually 2-3 pieces).
Tighten the bolts in a diagonal sequence step by step. M12-sized bolts must be tightened to a torque of 25-30N·m. Note that excessive torque may cause the starter housing to crack, while insufficient torque will lead to vibration during operation and affect service life.
Locate the "B+" terminal and "S" terminal on the starter solenoid switch. Firmly connect the thick power cable to the "B+" terminal, ensuring the insulation sleeve at the connection is intact; connect the control wire (thin wire) to the "S" terminal to avoid poor contact or loose connections.
After connection, inspect the wiring: ensure no looseness, no wire entanglement, and no oxidation on the terminals. Apply a small amount of conductive paste if necessary to improve contact performance.
Manually toggle the drive gear to ensure it rotates flexibly without jamming. Push the armature to the bottom and use a feeler gauge to measure the gap between the drive gear and the lock nut, which must be maintained at 1.5-2.5mm. Meanwhile, check the distance between the end face of the drive gear and the end face of the engine ring gear (standard value: 4±1mm). If the gap is inconsistent, adjust it via the limit screw on the starter.
Reconnect the negative terminal of the storage battery and perform an ignition startup test. The normal startup time should be ≤5 seconds without abnormal noise, and no intense sparks should occur between the brushes and the commutator. If the startup fails once, wait for the gear to reset before retrying, with an interval of at least 30 seconds between two startups to prevent the starter from overheating.
After the engine starts, observe whether the drive gear can retract automatically to avoid continuous contact with the flywheel causing component wear. The installation is completed once no abnormalities are confirmed.
Strictly implement "power-off operation" throughout the process: Disconnect the negative cable of the storage battery before installation, and wait 1-2 minutes after disconnection to release residual charges in the circuit. This prevents short-circuit sparking during wiring, which may damage the starter solenoid switch or storage battery.
Avoid live working: It is strictly prohibited to plug/unplug wiring terminals or adjust components without disconnecting the power supply, to prevent electric shock or circuit burnout caused by hand contact with conductive parts.
Wear protective equipment: During installation, wear insulating gloves and goggles to avoid oil contamination on the skin and prevent bolts or tools from falling and damaging precision components in the engine compartment.
Requirements for mounting surface fit: The starter and engine mounting surface must be fully fitted without warping or gaps. If there is rust or depression, grind it flat first; otherwise, excessive vibration during operation will damage the housing and internal bearings.
Bolt tightening standards:
Use a calibrated torque wrench and strictly tighten the bolts in a diagonal sequence step by step to a torque of 25-30N·m. Do not strike with brute force or over-tighten, to prevent bolt thread stripping or starter housing cracking.
The bolts must be used with matching lock washers (such as spring washers, lock nuts). Apply thread locker if necessary to prevent bolt loosening due to engine vibration during operation.
Gear meshing gap calibration:
The end face gap between the drive gear and flywheel ring gear (4±1mm) and the gap between the gear and lock nut (1.5-2.5mm) must strictly meet the standards. Excessively large gaps may cause abnormal impact noise during gear meshing, while excessively small gaps will result in gear jamming and accelerated wear.
If the gap is inconsistent, only adjust it via the limit screw equipped on the starter. Grinding the gear or ring gear for adaptation is prohibited.
Wiring matching specifications:
The power cable shall be a copper core cable with a cross-section ≥16mm² and a length not exceeding 1.2 meters. Avoid excessive voltage drop caused by too thin or too long wire diameter, which will affect the starter output power (the allowable voltage drop of 24V system is ≤0.5V).
The control wire must be firmly connected, with no oxidation or loosening at the terminals. If the terminals are rusted, grind them with fine sandpaper before connection. Apply conductive paste if necessary to improve conductivity.
Strictly prohibit reverse polarity connection: The "B+" terminal must be connected to the power cable on the positive side of the storage battery, and the "S" terminal to the control wire of the starter relay. Reverse connection will directly burn the solenoid switch coil and commutator, resulting in starter scrapping.
Insulation protection: Ensure the insulation sleeves of all wiring terminals are intact without damage or exposure. After connection, wrap them with insulating tape or heat shrinkable tube to prevent short circuit caused by friction with the engine housing.
Starter storage and inspection: Before installation, confirm that the starter is not damp or impacted, the drive gear is not deformed and has no missing teeth, and the brushes are in good contact with the commutator (no severe wear or carbon deposition). If stored for a long time, rotate the gear first to confirm flexible operation without jamming.
Prevent foreign objects from entering: During installation, prevent dust, oil, and metal debris from entering the starter interior, especially the brush holder and gear meshing parts. Otherwise, it will accelerate brush wear and cause gear jamming.
References：
Chongqing Cummins Engine Top 10 Components Maintenance and Fault Diagnosis Manual:
This technical manual, published on , serves as one of the core references. It explicitly specifies key parameters such as the required battery capacity (≥180Ah), CCA (Cold Cranking Amps) rating (1300A), the distance between the starter gear end face and the engine ring gear end face (4±1mm), and the maximum single startup duration (≤5 seconds)—all of which fully align with the corresponding data in the previous answers. Additionally, it covers relevant precautions for wiring connections and startup procedures.
Technical articles on disassembly and assembly of diesel generator starter motors:
Professional articles published by Chongqing Cummins Power and Diesel Generator Technology Network detail the assembly process, gap adjustment, and disassembly/assembly taboos for Cummins series starters. For example, the specified gap standard (1.5-2.5mm) between the drive gear and lock nut, the requirement to assemble in the reverse order of disassembly, and the prohibition of striking the starter are all integrated into the previous installation methods and precautions. These articles provide important references for operational steps and component protection content.
Industry specifications for general diesel engine starter installation:
General installation guides for starters published on platforms such as offer a universal operational framework, including power-off preparation, cleaning of mounting surfaces, bolt tightening to specified torque, and secure wiring connections. The previous answers drew on this standard framework and combined it with the exclusive parameters of the 24V 6.5KW Cummins starter to form a complete installation process tailored to this model.
Overall, the content is a systematic integration of professional technical key points for Cummins starter maintenance. It meets the actual installation requirements of this specific starter model and is consistent with the mainstream maintenance and operation standards for Cummins starters in the industry.
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