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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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M81R3005-R
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Quality :
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REMANUFACTURE
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Delivery time :
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10DAY
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The Yuchai 4S-2000 24V 4.5KW starter is mainly suitable for Yuchai series diesel engines and is commonly applied in commercial vehicles and other models. Its installation follows the core logic of diesel vehicle starter installation, while attention should be paid to the fixing torque and circuit connection details matching the adapted engine models. Below is the detailed installation method. It is recommended to wear protective gloves and goggles before operation:
Component Verification and InspectionFirst, confirm that the new starter is of Yuchai 4S-2000 specification and meets the voltage and power parameters of 24V 4.5KW. Carefully check that the starter housing has no cracks, the terminals are free of oxidation and rust, and the internal components have no loose parts or abnormal noises, so as to avoid adverse effects on post-installation use due to component defects.
Tool and Consumable PreparationPrepare tools such as 12-15mm socket wrenches, torque wrenches, Phillips screwdrivers, etc. Meanwhile, prepare cleaning cloths, conductive paste and a small amount of lithium-based grease, which are respectively used for cleaning the mounting surface, preventing terminal oxidation and lubricating gears.
Power-off OperationTurn off the vehicle's main power supply and disconnect the negative battery cable. This is a critical preliminary step to avoid safety hazards such as short circuits and accidental starting during installation.
Positioning and CleaningLocate the starter mounting position at the junction of the engine and transmission. Thoroughly wipe off oil stains, dust and rust on the mounting surface with a cleaning cloth to ensure the surface is flat and prevent the starter from vibrating during operation after subsequent fixation.
Positioning and PlacementPlace the new starter steadily at the mounting position and align it precisely with the bolt holes. If there is an old starter, refer to the orientation of its terminal end to ensure that the terminal end of the new starter is reasonably oriented, reserving appropriate space for subsequent circuit connection and avoiding wire harness entanglement and interference.
Insert the fixing bolts and initially tighten them by hand to prevent the starter from shifting. Then use a torque wrench for final tightening. Referring to the installation standards for starters of similar commercial vehicles, the torque should be controlled at 35-45N·m; if the mounting holes are for M10 bolts, the torque can be adjusted to 45±5N·m. If there are multiple bolts, tighten them alternately diagonally to ensure uniform force on the starter housing and avoid housing deformation caused by excessive local stress.
Main Power Cable ConnectionFirmly connect the thick power cable from the battery side to the B+ main terminal of the starter, and fasten it with a nut. The torque should be controlled within the range of 9.8-12N·m to avoid terminal breakage due to excessive torque or poor contact heating due to insufficient torque. Apply a small amount of conductive paste to the connection to enhance conductivity and prevent oxidation.
Control Circuit ConnectionAlign the control wire harness plug with the corresponding interface on the starter, insert it smoothly and ensure the clip locks in place. Arrange the wire harness routing to avoid interference with components such as the transmission counterweight. If there is a wire harness bracket, reinstall and fix it in its original position with a torque of approximately 8.4N·m.
Reconnect the negative battery cable and ensure it is securely fastened. Start the vehicle for testing, observe whether the starter runs smoothly without gear jamming or abnormal noise, and confirm that the engine can start successfully. If problems such as weak starting or no response occur, cut off the power immediately and check whether the circuit connection is loose or the installation position is offset.
After successful testing, reinstall components such as the vehicle's lower guard plate and battery bracket that were removed before installation, and tighten the relevant bolts. Finally, sort out the wire harness again to ensure that it does not interfere with other moving parts of the engine, thus completing the entire installation process.
Power-off Operation Must Be Implemented Throughout the Entire ProcessTurn off the vehicle's main power supply and disconnect the negative battery cable before installation. Never touch the starter terminals before power restoration testing to prevent short circuits that may generate sparks, ablate electrical components, or cause accidental starter activation leading to mechanical damage.
Strict Verification of Model and CompatibilityReconfirm that the starter model is Yuchai 4S-2000 with voltage and power parameters of 24V 4.5KW before installation. Meanwhile, check the matching degree between the drive gear tooth profile, mounting bolt holes and the engine flywheel housing. This avoids abnormal gear meshing clearance and housing deformation due to model mismatch.
Strict Adherence to Torque Standards for Bolt Tightening
The housing fixing bolts should be tightened alternately diagonally, with torque controlled within the range of 35–45N·m. For M10 bolts, the torque can be adjusted to 45±5N·m. Excessive torque may cause housing cracking and thread slipping, while insufficient torque will lead to starter vibration and abnormal noise during operation, and even wear of the flywheel ring gear.
The torque for the main terminal (B+) nut should be 9.8–12N·m. Loose fastening may result in overheating and ablation, whereas over-tightening could crack the terminal insulation layer. The control wire harness plug must be securely locked with its clip, and the wire harness bracket should be fixed with a torque of approximately 8.4N·m 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, directly rendering the starter unusable.
Prohibition of Reverse or Incorrect Circuit Connection
The main power cable (thick cable) must be connected to the B+ main terminal, and the control wire harness to the auxiliary terminal. Reverse connection is strictly forbidden, as it will instantly burn out the electromagnetic switch or the vehicle's circuit fuse.
Clean the oxide layer on the terminal surface before connection, and apply a small amount of conductive paste to reduce contact resistance. When arranging the wire harness, keep it away from high-temperature components such as exhaust pipes to prevent aging and damage of the harness insulation layer which may lead to short circuits.
References：
The previously provided installation precautions for the Yuchai 4S-2000 24V 4.5KW starter are not derived from an exclusive manual or a single authoritative document officially released by Yuchai for this specific starter model. Instead, they are comprehensively summarized and organized based on general automotive starter installation specifications, relevant adaptability characteristics of Yuchai engines, and technical key points from multiple automotive maintenance platforms. The specific reference basis is as follows:
Content such as power-off operation, model verification, diagonal alternating bolt tightening, and terminal fixing according to specified torque is consistent with the general starter installation procedures released by platforms like Autohome and PCauto Encyclopedia. For example, the mentioned torque parameters for the main terminal nut and wire harness bracket fixing match the torque standards for 24V starter installation specified in PCauto Encyclopedia. The requirement prohibiting tapping the starter housing also aligns with the disassembly and assembly taboos for starters clearly stated on Autohome.
For starters matching commercial vehicle diesel engines like Yuchai, the requirement in the document to apply only a small amount of lithium-based grease to the drive gear tooth surface and strictly prohibit oil injection into internal components conforms to the lubrication and protection logic for high-power commercial vehicle starters. Meanwhile, combined with the characteristic that diesel engine starters have high adaptability requirements with the flywheel housing, the document emphasizes the verification of tooth profile and mounting bolt hole matching. This is a key point distinguishing diesel vehicle starter installation from that of some passenger vehicles, and also a core precaution mentioned in multiple commercial vehicle maintenance forums.
Safety measures in the document, such as disconnecting the negative battery cable during disassembly and assembly and troubleshooting potential hazards before testing, are general guidelines for automotive electrical component installation. Such steps are listed as primary preliminary processes in most automotive maintenance tutorials, aiming to avoid electrical short circuits that may damage components or cause safety accidents, and are recognized as basic operational specifications in the industry.
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