Starter 28100-1443 28100-1870 28100-2044 28100-2072 for Hino EH300 EH700 EC100

Hino 24V Starter Installation Guide

• Safety Premise: Turn off the engine, engage the parking brake, and place wheel chocks. Disconnect the negative battery terminal and mark it to prevent short circuits and accidental starting.

• Tools: Torque wrench, socket set (with corresponding specifications), Phillips/slotted screwdriver, plastic pry bar, rag and cleaner, anti-rust lubricant, copper grease (optional).

• Materials: Compatible 24V starter (verify part number and gear teeth), new gasket/seal (if applicable), terminal protectors, thread locker (for critical parts).

• Verification: Ensure the starter voltage is 24V, the gear teeth match the flywheel ring gear, and the mounting holes align with the bolt specifications. Inspect the new starter for any visible damage, ensure smooth operation of the solenoid switch, and confirm free return of the one-way clutch.

1. Cleaning and Pre-treatment

• Clean the starter mounting surface and bolt holes on the engine block/transmission side to remove oil, rust, and old sealant. Threads may need tapping for cleaning if necessary.

• Apply a thin layer of high-temperature sealant or copper grease to the mounting surface and new gasket (for anti-seizing and sealing). Apply anti-rust lubricant or thread locker to the bolt threads (as per manual requirements).

2. Positioning and Tightening

• Carefully place the starter into the mounting position, aligning it with the bolt holes. Avoid bumping the solenoid switch and terminals.

• Manually thread all mounting bolts until finger-tight, ensuring no interference between the ring gear and the starter drive gear. Tighten in the specified order and torque (Hino common reference value: approximately 154 N·m for mounting bolts; always refer to the vehicle manual for specifics).

3. Electrical Connection

• Connect the small control wire plug (solenoid switch terminal) first, ensuring the retaining clip is securely engaged and the waterproof seal is intact.

• Connect the main power cable (thick wire) next. Clean the terminals before tightening the nut to the specified torque (reference: 16–22 N·m) to prevent poor contact and overheating. Install a terminal protector to prevent short circuits.

• Check the harness routing to ensure it does not interfere with high-temperature/moving components such as the timing belt, fan, and exhaust manifold, and secure it with cable ties.

4. Reconnect Power and Testing

• After confirming all connections are correct, reconnect the negative battery terminal and tighten it securely.

• No-load Test: With the key in the "ON" position, briefly touch the start position. The starter should engage quickly, run smoothly without abnormal noise, and the drive gear should retract immediately when released.

• Vehicle Test: Start the engine. Observe that the start is strong with no slipping or gear clash. At idle, check that the starter does not have abnormal temperature rise or noise.

• Final Inspection: After 熄火，check the temperature of the wiring terminals, the tightness of the bolts, and the harness interference.

Hino 24V Starter Installation Key Precautions

• Power Disconnection First: Before removing or installing any electrical components, always disconnect the negative battery cable and insulate/mark it to prevent short circuits and accidental starting.

• Vehicle Securing: Park the vehicle on a flat, hard surface, engage the parking brake, and place wheel chocks at the front and rear wheels to ensure stability.

• Prevent Falling and Pinching: Starters are heavy. Use a stand or have two or more people assist with lifting and lowering to avoid crushing injuries or dropped objects.

• Wear Protective Gear: It is recommended to wear insulated gloves and safety goggles to protect hands and eyes from potential hazards.

• Verify Model Compatibility: Ensure the new starter's model, voltage (24V), and gear teeth exactly match the flywheel ring gear. The part number must align with the vehicle manual.

• Check Starter Condition:

• Visually inspect the starter for any cracks, deformities, or damage.

• Manually test the solenoid switch for smooth operation and ensure the one-way clutch returns freely.

• Check for any internal binding within the starter.

• Cleaning and Pre-treatment:

• Thoroughly clean the starter mounting surface and bolt holes on the engine block/transmission side to remove oil, rust, and old sealant.

• Clean the threads of bolts and nuts.

• Apply a thin layer of high-temperature sealant or copper grease to the mounting surface and new gasket (for anti-seizing and sealing).

• Apply anti-rust lubricant or thread locker to the bolt threads (as per manual requirements).

• Precise Alignment: Carefully place the starter into the mounting position, ensuring the starter drive gear properly meshes with the flywheel ring gear and there is no interference.

• Bolt Tightening:

• Manually thread all mounting bolts until finger-tight to confirm alignment is correct.

• Always use a torque wrench to tighten in the specified order and torque (typically a diagonal pattern) in multiple steps. Never use brute force to tighten them in one go.

• Reference Torque Value: Mounting bolts (approx. 154 N·m; always refer to your vehicle's service manual for specifics).

• Electrical Connection:

• Connect Control Wire Before Main Power: Ensure the small control wire plug (solenoid switch terminal) is securely connected with the retaining clip in place. Then connect the main power cable (thick wire).

• Clean the main power terminals to remove any oxidation. After connection, use a torque wrench to tighten the nut to the specified torque (reference: 16–22 N·m) to prevent poor contact and overheating.

• Install terminal protectors to prevent short circuits.

• Check the harness routing to ensure it does not interfere with high-temperature components (e.g., exhaust manifold) or moving parts (e.g., belt, fan), and secure it with cable ties.

• No-load Test: After reconnecting the negative battery terminal, perform a no-load test. Turn the key to the "ON" position and briefly touch the start position. The starter should engage quickly, run smoothly without abnormal noise, and the drive gear should retract immediately when released.

• Vehicle Test: Start the engine. Observe that the start is strong with no slipping or gear clash. Run at idle for a period and check that the starter does not have abnormal temperature rise or noise.

• Final Inspection: After 熄火，check the tightness of all bolts, the temperature of the wiring terminals, and the harness interference again.

• Never perform a power-on test with the starter unbolted.

• Never strike the starter or its components with hard objects such as a hammer.

• Never use bolts or nuts that do not meet specifications.

• Never use standard wire harness tape or uninsulated wires in high-temperature areas (e.g., near the exhaust manifold).

• Never allow any interference between the starter drive gear and the flywheel ring gear.

References：

Content Source and Basis

• General Process: The closed-loop process of Power Off → Cleaning → Alignment → Tightening → Wiring → Testing is the standard operating sequence for starter installation in commercial vehicles, applicable to Hino 24V models.

• Key Parameters and Points: Reference torque values such as approximately 154 N·m for mounting bolts, 16–22 N·m for main power terminals, connecting control wires before main power cables, and no-load/vehicle testing are all derived from common after-sales reference values and industry consensus for Hino (always refer to the vehicle manual for specifics).

• Safety and Craftsmanship: Measures such as power disconnection to prevent short circuits, diagonal tightening, keeping away from high-temperature/moving components, and terminal cleaning and anti-loosening are universal safety requirements for automotive electrical and engine accessory installations.

Difference from Official Manuals

• Official manuals provide precise part numbers, bolt specifications, torque values, harness pin definitions, and disassembly/assembly paths according to specific vehicle/engine models (e.g., J08C, P11C), while the version I provide is a general one for quick start-up and self-inspection.

• Official manuals usually contain in-depth content such as trouble codes, circuit diagrams, and tolerance parameters, whereas I offer simplified installation steps and precautions more suitable for on-site construction.

Tracing Sources and Verification Suggestions

• Vehicle/Engine Model (e.g., Hino J08C, FD1J)

• Manual Number/Chapter Number (e.g., 308-01, 308-02)

• Original Text Fragment (copy the sentence you want to verify)