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Type :
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starter
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Specification :
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24V 6.6KW
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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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5263669
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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 24V 6.6KW Cummins starter is mostly compatible with Cummins diesel generator sets or heavy-duty diesel engines. Installation must comply with principles such as power-off protection, precise alignment, and standardized wiring. Below are the detailed installation steps, including pre-installation preparation and post-installation commissioning:
Prepare tools such as a socket wrench, screwdriver, brush hook, and feeler gauge. Meanwhile, prepare matching gaskets, spacers, grease, and thread locker. Verify the model of the new starter to ensure its 24V voltage and 6.6KW power match the engine, with no external damage and complete components.
Disconnect the negative terminal of the storage battery to avoid short circuits or accidental startup during installation. Clean the work area to keep it dry and free of debris, preventing dust and oil from entering the starter. Additionally, check the storage battery status: it must have a capacity of ≥180Ah, a CCA (Cold Cranking Amps) rating of 1300A, and be fully charged.
Locate the starter mounting position on the engine flywheel housing. Remove dirt, rust, and residual oil from the mounting surface; thoroughly clean any remaining old gaskets to ensure a flat mounting surface, avoiding looseness or leakage after installation.
Fit the starter closely to the mounting surface, ensuring the starter axis is parallel to the flywheel ring gear (avoid misalignment). If spacers or gaskets are used, install them with the same thickness as during disassembly—do not arbitrarily change the thickness, as this may damage the starter or engine.
Align the starter mounting holes with those on the flywheel housing, insert the fixing bolts, and tighten them to the specified torque with a wrench. For cast iron flywheel housings, the bolt torque should generally reach 215N·m. Tighten the bolts in a symmetrical, step-by-step manner to prevent uneven stress on the mounting surface.
If the starter was previously disassembled, complete internal assembly first:
Apply a small amount of grease to friction parts such as bushings and armature journals.
Install the intermediate support plate, overrunning clutch, and retaining ring in sequence, and secure the shaft end lock ring.
Slide the shift fork into the fork sleeve of the overrunning clutch, then insert the rotor into the drive end cover and tighten the support plate screws.
Finally, install the brushes: grind the contact surface of insulated brushes (with sleeves) and insert them into the insulated brush holders.
Use wires with a cross-sectional area of more than 50mm² to connect the positive terminal of the storage battery to the starter terminal.
Use wires with a cross-sectional area of no less than 2.5mm² to connect the solenoid switch to the starter relay.
Clean oxidation from the terminals before wiring, then tighten the nuts to ensure a secure connection. Minimize wire length to reduce resistance loss.
Confirm the armature is securely assembled; pull the armature by hand to check for jamming. After aligning the armature pull rod with the shift fork, install the solenoid switch and tighten the fixing screws. Finally, reconnect the connecting copper plate to the solenoid switch and motor terminals.
Use a feeler gauge to check the gap between the drive gear and limit ring; adjust by rotating the connecting rod if it does not meet specifications.
Push the armature fully home to ensure the gap between the drive gear and lock nut is 1.5–2.5mm.
Verify the distance between the starter gear end face and the engine ring gear end face is 4±1mm; adjust with the limit screw if necessary.
Toggle the drive gear to ensure smooth 360° rotation without jamming. If the armature axial gap is abnormal, adjust by adding or removing end cover gaskets.
Reconnect the negative terminal of the storage battery and start the engine for testing. Qualification criteria:
The starter operates with sufficient power and no abnormal noise.
No intense sparks occur between the brushes and commutator.
No impact noise between the drive gear and flywheel ring gear.
If issues such as gear jamming or weak starting occur, immediately cut off power and inspect the wiring or gaps.
Throughout the installation process, the negative cable of the storage battery must be disconnected first, and a waiting period of more than 5 minutes is required after disconnection (to discharge residual circuit charge). Live operation of electrical circuits or disassembly of starter components is strictly prohibited to avoid electric shock or fire risks caused by short-circuit sparks.
This starter is a 24V high-voltage and high-current equipment. The main circuit connecting the positive terminal of the storage battery must use special cables resistant to high temperature and aging (cross-sectional area ≥50mm²); thin wires or damaged wires are strictly forbidden. Insulating sleeves must be installed at the terminals to prevent accidental contact and short circuits, and the wiring layout must be kept away from high-temperature components such as the engine exhaust pipe and turbocharger (distance ≥10cm).
The work area must be dry and well-ventilated, free of flammable and explosive materials (such as gasoline and oil-stained rags). Installation in rainy or humid environments is avoided to prevent moisture from entering the starter and causing insulation failure.
Use tools with insulated handles for operation. When tightening bolts, avoid tools touching the terminals to cause short circuits. When disassembling/installing the solenoid switch, do not pry the armature with metal tools to prevent damage to the electromagnetic coil.
The mounting surface of the flywheel housing must be thoroughly cleaned (free of rust, oil, and residual sealant). A new gasket must be replaced during installation, and excessive grease must not be applied to the gasket surface (only a thin layer of sealant on the edge to assist sealing) to avoid oil leakage or loosening of the mounting surface due to seal failure.
High-strength bolts of original factory specifications (usually M12×1.75, grade 8.8) must be used for fixing bolts; replacement with ordinary bolts is strictly prohibited. During tightening, the principle of "symmetrical step-by-step tightening" must be followed, and the specified torque must be gradually achieved in 3 steps (215N·m for cast iron flywheel housings, 180N·m for aluminum alloy flywheel housings) to prevent deformation of the mounting surface or loosening of bolts.
References：
Doc88 Chongqing Cummins Engine Maintenance ManualThis manual is one of the core reference bases. It clearly specifies numerous key parameters and installation requirements, such as the distance between the starter gear end face and the engine ring gear end face being 4±1 mm, the storage battery capacity ≥180Ah with a CCA rating of 1300A, the main circuit wire cross-sectional area exceeding 50 mm², and the connecting wire between the solenoid switch and the starter relay having a cross-sectional area of no less than 2.5 mm². All these parameters accurately match the core installation specifications in the previous answers.
Adjustment and Testing of Diesel Generator Starter Motor After Disassembly and AssemblyThis technical article details operations such as the disassembly, reassembly, and gap adjustment of Cummins-related starters. Assembly details including applying grease to friction parts during starter reassembly, grinding the contact surface of brushes before installation and inserting them into insulated brush holders, checking the firmness of the armature after assembly, and the 1.5-2.5 mm gap between the drive gear and the lock nut are highly consistent with the content related to internal component assembly and gap adjustment in the previous answers.
Disassembly Sequence and Detailed Steps for Diesel Engine StartersPublished by Chongqing Cummins Power, this article supplements precautions such as preparation of disassembly tools, parts cleaning methods, and avoiding tapping the starter. It also clarifies that the starter reassembly must be performed in the reverse order of disassembly. These contents have improved the key points related to safe operation and assembly processes in the previous answers.
Disassembly, Inspection, and Installation of Cummins Engine Starter MotorsThe article mentions that the thickness of the spacer during installation must be consistent with that during disassembly. This detail has been incorporated into the precautions for aligning and placing the starter in the previous answers to avoid equipment damage caused by mismatched accessory specifications.
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