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Type :
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STARTER ARMATURE
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Specification :
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24V 4.5KW
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Number of feet :
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9T
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Brand :
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NUOJIN
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Number :
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QDJ2636C
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Quality :
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Remanufacture
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Delivery time :
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7--10DAY
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The installation of the Weichai 24V starter motor must be performed in accordance with the characteristics of the diesel engine model (e.g., WP4, WP6 series) and focuses on four core steps: power-off preparation, precise installation, wiring connection, and post-installation testing. Below is a universal installation method applicable to most Weichai models, integrated with model-specific key considerations:
First, confirm that the model of the new starter motor is compatible with the Weichai engine. For example, the installation requirements for starters used with Weichai WP4 and WP6 models differ—avoid installation failures caused by mismatched models. Prepare tools including 17mm/19mm socket wrenches, a torque wrench, alcohol-based cleaner, lithium-based grease, and new seals. For Weichai models equipped with sealed flywheel housings, prepare Weichai-specified sealant.
Disconnect the negative battery cable to completely eliminate the risk of short circuits or sparks caused by tools contacting the starter terminals during installation—this is a critical safety step for electrical operations.
Wipe the starter mounting surface and flywheel housing mating surface with alcohol. If there are burrs on the mating surface, remove them using 240# fine oilstone. For flywheel housings requiring sealing, apply a uniform layer of sealant to the mating surface in advance. Additionally, apply lithium-based grease to the starter gear to enhance operational smoothness.
Align the gear end of the starter with the flywheel ring gear, adjusting the position to ensure they are parallel. This guarantees smooth meshing and prevents gear jamming issues.
For Weichai models with studs: Pre-install the studs on the flywheel housing first, then fit the starter over the studs and secure with hex nuts. Tighten bolts according to their specifications:
M10 bolts: Tighten to 80–85N·m in the direction indicated by the arrow.
M12 bolts: Tighten to 140–145N·m in sequence from 1 to 6.
For standard models (typically secured with 2–3 bolts): Tighten in a diagonal, step-by-step manner to prevent housing cracking due to uneven force distribution.
Locate the "B+" terminal on the starter solenoid switch, firmly connect the thick power cable, and check that the insulation sleeve is intact. Then connect the thin control wire to the "S" terminal—ensure the connection is secure, as loose connections will prevent the starter from operating normally.
The wiring harnesses of some Weichai models have dedicated markings. During installation, connect the wires to the positions corresponding to the marks made during disassembly to avoid reverse wiring, which could burn out the solenoid switch or internal coils.
If the starter was previously disassembled:
Align the brush holder with the wire notch on the end cover, and securely fasten the gaskets and clips after installing the cover.
Pay attention to the number of thrust washers at the rotor commutator and ensure the one-way clutch is properly installed.
Do not strike or force components—this may damage internal planetary gears and bearings.
Reconnect the negative battery cable and start the engine. Check that the startup time is ≤5 seconds and there are no abnormal noises (e.g., gear grinding). If multiple starts are required, allow an interval of ≥30 seconds between attempts to prevent overheating and damage to the starter.
After shutting down the engine:
Confirm that the starter drive gear has fully retracted to prevent continuous friction with the flywheel ring gear.
Manually toggle the gear to check for flexible rotation without jamming. If jamming occurs, adjust the armature axial clearance by modifying the thickness of the end cover gasket.
After the engine has operated for 10–15 minutes:
Check that the starter housing temperature is normal.
Verify that bolts are not loose.
Ensure wiring terminals show no signs of overheating or discoloration.
This confirms the installation is stable and reliable.
The installation of the Weichai 24V starter motor must strictly comply with the characteristics of the diesel engine model (e.g., WP4, WP6, WP10 series) and focus on safety operations, installation precision, component protection, and compatibility requirements. Specific precautions are as follows:
Disconnect the negative battery cable throughout the entire installation process. Before operation, use a multimeter to confirm no residual voltage exists at the starter terminals to avoid short circuits, sparks, or electric shock caused by tools contacting the "B+" and "S" terminals.
Do not touch the metal parts of the terminals with bare hands when connecting wires. If the insulation sleeve is damaged, replace it immediately to prevent electric leakage or short circuits that could burn out the solenoid switch and coils.
Avoid installation in rainy, humid, or dusty environments to prevent moisture and dust from entering the starter, which may cause bearing jamming and coil short circuits. For outdoor operations, set up a temporary shelter.
Wear non-slip gloves and safety goggles to prevent hand scratches from falling bolts and eye irritation from oil splatters. Smoking and open flames are strictly prohibited in the installation area, and keep a safe distance from the battery (to avoid hydrogen combustion and explosion).
Calibrate the torque wrench in advance. Do not use a socket extension bar to over-tighten bolts, as this may cause bolt breakage or thread damage. Avoid striking the starter terminals, housing, or other parts with metal tools to prevent spark generation.
The mounting surfaces (starter flange and flywheel housing mating surface) must be thoroughly cleaned to remove oil stains, rust, metal debris, and residual old sealant. Otherwise, poor fitment may occur, leading to vibration noise or housing deformation.
For Weichai models equipped with sealed flywheel housings, apply a uniform layer of Weichai-specified sealant (thickness: 0.3-0.5mm) to the mating surface. Prevent sealant from entering the interior of the flywheel housing or the starter gear meshing area to avoid component jamming after sealant curing.
Replace seals (O-rings, gaskets) with new ones of the same model as the original parts. Reusing old seals is prohibited to prevent oil leakage.
References：
The safety precautions for Weichai 24V starter motor installation, as previously provided, are not derived from a single official original document. Instead, they are comprehensive key points integrated based on Weichai engine model-specific maintenance data, universal industry repair standards, and publicly available practical technical content. The reference sources for the core information can be further verified through the following types of materials:
Weichai's exclusive engine maintenance manuals for mainstream models such as WP4, WP6, and WP10 include basic installation requirements for the matching 24V starter motors. For example:
The training material Weichai WP4, WP6 Diesel Engine Training published on Docin.com mentions details such as flywheel housing seal types and cleaning requirements. These align with key points in the precautions, such as "sealed flywheel housings requiring Weichai-specified sealant" and "cleaning the mounting surface."
The requirement for communication compatibility between the starter and ECU in National VI emission standard models is consistent with the general specification in Weichai's National VI engine maintenance manuals, which mandates signal verification with a diagnostic tool after electrical component installation.
Numerous practical maintenance sharing materials for Weichai starters can confirm the disassembly and reassembly details in the precautions. For example:
Disassembly and assembly videos of Weichai Bosch starters on Douyin (TikTok) highlight operational key points such as aligning the brush holder with the wire notch on the end cover and securely fastening gaskets and clips after cover installation. These are highly consistent with the relevant specifications for post-disassembly reinstallation in the precautions.
Additionally, operations mentioned in the videos—such as applying lubricating oil to gears and cleaning the stator—match the component preprocessing requirements outlined in the precautions.
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