Installation Method for KAMAZ 24V Starter

I. Pre-installation Preparation

Tools and Materials Preparation

• Special Tools: Socket wrench (matching the starter fixing bolts), torque wrench, Phillips/flathead screwdriver, terminal crimping tool, insulating tape.

• Materials: Bolts and nuts meeting specifications (strength grade recommended by the original factory), copper wiring terminals, high-temperature lubricating grease, anti-rust agent.

• Protective Equipment: Insulated gloves, safety goggles, to prevent oil contamination and electric shock hazards.

Condition Inspection

1. Inspect the appearance of the new starter to ensure there is no housing crack, terminal deformation, or damage to the gear (drive pinion).

2. Clean the starter mounting surface on the engine flywheel housing, remove oil stains, rust, and residual old gaskets, and apply a small amount of anti-rust agent.

3. Check the tooth surface of the flywheel ring gear. If there is severe wear or tooth chipping, replace it first; otherwise, it will cause starter gear meshing failure.

Power-off Operation

II. Installation Steps

Pre-installation Drive Gear Lubrication

Starter Positioning and Fixing

1. Align the starter mounting flange with the mounting holes on the engine flywheel housing, push it in slowly, and ensure the relative position between the starter drive gear and the flywheel ring gear is correct without jamming.

2. Manually screw in 2–3 fixing bolts for positioning. Note that the bolt insertion direction should be consistent with that of the original factory, and no skew is allowed.

3. Tighten the fixing bolts in a cross-symmetrical sequence with a torque wrench. The torque value must comply with KAMAZ’s original factory standards (typically 80–120 N·m for heavy-duty vehicle starter fixing bolts; refer to the corresponding vehicle manual for exact values). Over-tightening is prohibited to prevent housing deformation.

Circuit Connection (Core Step)

1. Main Power Cable Connection: Connect the thick cable from the positive terminal of the battery to the starter’s main terminal (marked "30" or "+") via a copper terminal. Tighten the terminal nut with a torque of 25–35 N·m to prevent loosening and overheating; wrap the connection with insulating tape or install an insulating sleeve.

2. Control Circuit Connection: Connect the thin control wire from the ignition switch to the starter’s solenoid switch terminal (marked "50" or "S"), tighten the small fixing nut, and ensure good contact.

3. Inspect all wiring terminals to ensure there is no loosening or exposed copper wire, avoiding circuit grounding and short circuits.

Reset the Battery Cable

III. Post-installation Commissioning

No-load Test

1. Confirm the vehicle is in neutral (manual transmission) or park (automatic transmission), and pull the handbrake tightly.

2. Briefly turn the ignition switch to the start position (no more than 5 seconds). Observe whether the starter drive gear pops out and rotates normally without abnormal noise or jamming; the gear must retract quickly when the ignition switch is released.

3. If the gear fails to pop out or abnormal noise occurs, cut off the power immediately and check the installation position or circuit connection.

Load Test

1. After completing the no-load test, start the engine. Observe whether the starter meshes smoothly and whether the starter disengages immediately after the engine starts.

2. Do not start the engine more than 2 times continuously, with an interval of at least 1 minute between each start to prevent starter overheating and burnout.

Sealing and Circuit Inspection

1. Check that there is no oil or air leakage between the starter mounting surface and the flywheel housing.

2. Re-tighten the wiring terminals and confirm that the circuits do not rub against the starter housing or high-temperature components.

Precautions for Installation of KAMAZ 24V Starter

I. Safety and Compatibility Precautions Before Installation

Strict Power-off Operation

Precise Model Matching

Component Condition Verification

1. For a new starter, inspect that there is no housing crack, terminal oxidation or deformation, and no tooth chipping or wear on the drive gear. For a used starter, test the one-way transmission performance of the clutch in advance to ensure smooth extension and retraction of the gear.

2. When cleaning the flywheel housing mounting surface, thoroughly remove residual old gaskets, oil stains and rust. If the flatness of the mounting surface exceeds the standard, repair it before installation; otherwise, it will cause vibration and abnormal noise during starter operation.

3. Check the flywheel ring gear. If the tooth surface wear exceeds 0.5 mm or there are more than 3 consecutive chipped teeth, replace the ring gear first. Failure to do so will lead to starter gear meshing slip and tooth striking failure.

II. Operational Precautions During Installation

Bolt Fastening Specifications

1. Use high-strength bolts recommended by the original factory for fixing bolts; do not replace them with ordinary bolts to prevent bolt breakage during startup.

2. Tighten the bolts in a cross-symmetrical sequence, and the torque value must strictly follow KAMAZ official standards (typically 80–120 N·m, refer to the vehicle-specific manual for exact values). Insufficient torque will cause starter loosening, while excessive torque will result in housing deformation and thread slipping.

Lubrication Operation Taboos

1. Only apply a small amount of high-temperature lithium-based grease to the drive gear and bearing parts. Never apply excessive grease or ordinary butter; excessive grease will be thrown into the clutch, causing one-way clutch slip and failure.

2. Do not apply grease to the solenoid switch’s pull-in iron core or wiring terminals, to avoid affecting circuit conduction or iron core pull-in performance.

Core Requirements for Circuit Connection

1. The main power cable (thick cable) must be connected to the starter’s main terminal (marked "30" or "+"), and the control circuit (thin wire) must be connected to the solenoid switch terminal (marked "50" or "S"). Reverse connection is strictly prohibited, as it will directly burn out the solenoid switch coil.

2. Use copper special terminals for wiring connections, crimp them firmly. Wrap the connection points with insulating tape or install insulating sleeves to prevent terminal loosening and grounding during vehicle operation.

   References：
   

3. The chapter on disassembly, assembly and commissioning of starter assemblies in the KAMAZ Service Manual (for 24V heavy-duty vehicle starters, covering mainstream models such as KAMAZ 5320/5321/6520) serves as the direct technical source for these precautions. It includes core specifications such as torque requirements, wiring rules, lubrication standards and testing procedures.

5. National Standard Basis

7. GOST 25379-82 Technical Requirements for Automobile Starters, the Russian national standard, specifies general mandatory standards for starter installation, electrical connection, safe operation and performance testing. It supplements industry-wide constraints (e.g., single startup duration limit, wiring insulation requirements, bolt strength criteria, etc.).

9. Supplementary Industry Basis

11. General specifications for heavy-duty commercial vehicle starter installation, including SAE J1171 (Starter Performance and Installation Standard) and ISO 8856 (Safety Standard for Automotive Electrical System Installation), are adopted to supplement the general safety and performance requirements not detailed in the original KAMAZ manual.

13. Supplementary Notes

15. The above precautions are compiled and refined based on the original factory manual, national standards and industry general specifications. They are not verbatim excerpts from a single document, but practical operational guidelines tailored for KAMAZ 24V starters.
17. For access to the original documents, please refer to the official KAMAZ service platform, the Russian GOST standard database, and the SAE/ISO standard libraries.