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Type :
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Starter Motor
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Specification :
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24V 4.5KW
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Number of feet :
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11T
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Brand :
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NUOJIN
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Number :
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QDJ2636A
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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 Foton 24V 4.5KW starter is mostly suitable for diesel heavy-duty trucks and other models under the Foton brand. Its installation process follows the same logic as that of general starters, with the core steps being reliable power-off protection, accurate alignment and fixation, and proper circuit connection. Below is the detailed installation method. It is recommended to wear gloves and goggles before operation:
First, verify the model of the new starter to confirm it is the 24V 4.5KW specification compatible with Foton models. Check that the starter housing has no cracks, the terminals are free of oxidation and corrosion, and the internal components are not loose.
Prepare tools such as 12-15mm socket wrenches, torque wrenches, Phillips screwdrivers, etc., and prepare a cleaning cloth to wipe off oil stains on the installation area.
Turn off the vehicle's main power supply and disconnect the negative battery cable to avoid safety hazards such as short circuits or accidental starting during installation.
Locate the starter mounting position at the junction of the engine and transmission. Wipe off oil, dust, and rust on the mounting surface with a cleaning cloth to ensure the surface is flat and prevent compromising the stability of the fixation.
Place the new starter steadily at the mounting position and align it precisely with the bolt holes. Note that the orientation of the starter's terminal end should be consistent with that of the old unit to avoid misalignment during subsequent circuit connection.
Insert the fixing bolts and hand-tighten them initially to prevent the starter from shifting.
Use a torque wrench to tighten the bolts. Referring to the installation standards for starters of similar commercial vehicles, the torque should be controlled at 35-45N·m. Excessive torque may damage the threads, while insufficient torque can cause vibration during operation. If there are multiple bolts, it is recommended to tighten them alternately diagonally for even force distribution.
First, connect the main power cable: securely attach the thick power cable from the battery side to the main terminal of the starter, fasten it with a nut at a torque of approximately 9.8N·m, and apply a small amount of conductive paste to the connection to prevent oxidation.
Then, connect the control wire harness plug: insert it smoothly into the wire harness interface on the starter and ensure the clip locks in place to avoid poor contact due to loosening.
If there are wire harness brackets and clips, reinstall and secure them in their original positions at a torque of approximately 8.4N·m. Arrange the wire harness properly to prevent interference with other components.
Reconnect the negative battery cable and ensure it is firmly fastened.
Start the vehicle for testing: observe whether the starter runs smoothly without abnormal noise and check if the engine starts successfully. If issues such as gear jamming or weak starting occur, cut off the power immediately and inspect the circuit connections and installation position.
After successful testing, reinstall any components such as the lower guard plate that were removed earlier to complete the installation.
Power-off Operation Must Be Performed FirstKeep the vehicle's main power supply off throughout the installation process and disconnect the negative battery cable to prevent short circuits that may cause sparks, ablation of electrical components, or accidental starting. Under no circumstances should the starter terminals be touched before power restoration testing.
Precise Matching of Model and Mounting PositionRecheck the compatibility between the starter model and the corresponding Foton vehicle before installation. Ensure that the tooth profile of the drive gear and the mounting bolt holes are fully matched with the engine flywheel housing. This prevents poor gear meshing and body deformation due to model mismatch.
Bolt Tightening Must Comply with Standard Torque
The housing fixing bolts should be tightened alternately diagonally, with the torque strictly controlled within the range of 35-45N·m. Excessive torque may cause thread slipping or housing cracking, while insufficient torque will lead to vibration, abnormal noise during starter operation, and even damage to the flywheel ring gear.
The torque for the main power terminal nut should be approximately 9.8N·m. Loose fastening may result in overheating and ablation, whereas over-tightening may crack the terminal insulation layer. The control wire harness plug must be locked securely with the clip to prevent loosening and falling off during vehicle operation.
Strict Control of Lubricant Dosage and Application PositionApply only a small amount of lithium-based grease to the tooth surface of the drive gear to improve meshing smoothness. Never inject grease into the overrunning clutch, electromagnetic switch, or coil components. Grease entering these internal parts will cause coil short circuits and overrunning clutch jamming failures.
Standardized and Orderly Circuit Connection
The main power cable (thick cable) must be connected to the starter's main terminal, and the control wire harness to the auxiliary terminal. Reversing the connections will burn out the electromagnetic switch or the vehicle's circuit fuse.
Ensure the terminals are clean and free of oxidation; a small amount of conductive paste can be applied to reduce contact resistance. When arranging the wire harness, avoid contact with high-temperature engine components (e.g., exhaust pipes) to prevent harness aging and damage.
Adequate Safety Protection During TestingWhen conducting power restoration and startup testing, keep the vehicle's parking brake engaged and the transmission in neutral. If issues such as starter idling, gear collision, or weak starting occur, cut off the power immediately and stop the test to inspect the meshing clearance, circuit connections, and battery voltage. Repeated forced starting is strictly prohibited.
Prohibit Rough Operation to Avoid Component DamageNever strike the starter housing or gear parts violently during installation to prevent damage to internal coils, bearings, and the one-way clutch. If the mounting position is misaligned, readjust the starter position instead of forcing the bolts into place.
Post-installation Recheck and ProtectionAfter successful testing, reinstall protective components such as the vehicle's lower guard plate to prevent sand, sediment, and water from entering the starter during operation. For vehicles operating in long-term humid or dusty environments, install waterproof sleeves on the terminals for additional protection.
Professional Reference and Personnel QualificationIf complex problems arise during installation (e.g., meshing clearance adjustment, circuit fault diagnosis), refer to the Foton original factory maintenance manual or contact professional maintenance personnel for operation. Non-professionals are prohibited from disassembling the internal structure of the starter.
References：
The installation method and precautions for the Foton 24V 4.5KW starter you enquired about are not derived from a specific Foton official manual or a single authoritative document. Instead, they are compiled and summarized based on the general installation specifications for automotive starters, the relevant adaptation characteristics of Foton commercial vehicles, and the universal technical key points from multiple auto maintenance platforms.
The core reference basis is as follows:
General Technical Standards for Starter InstallationContent such as power-off operation prior to installation, model verification, diagonal bolt tightening, and terminal fixation according to specified torque is consistent with the general starter installation procedures released by platforms like PCauto and Autohome. For example, the recommended torque of approximately 9.8N·m for the main terminal nut mentioned in the text matches the terminal fixing torque standard specified in the PCauto Encyclopedia.
Special Precautions for Commercial Vehicle StartersFor high-power 24V 4.5KW starters adapted to heavy-duty trucks, the emphasized requirements including gear lubrication and prohibition of striking the starter body are in line with the installation and protection requirements for commercial vehicle starters stated on platforms such as Daowen Network and Autohome. A typical example is the strict ban on violent hammering to prevent damage to internal coils, which is a common taboo in the installation of high-power starters for commercial vehicles.
Safety Specifications for Auto Maintenance OperationsSafety measures such as disconnecting the negative battery cable and troubleshooting potential hazards before power restoration testing are universal safety guidelines for the installation of automotive electrical components. These steps are listed as core preliminary procedures in starter disassembly and assembly tutorials on numerous auto maintenance platforms.
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