Hino Truck 750/EF550/EK100 Starter Installation Guide

I. Applicable Starter Specifications

• Voltage: 24V

• Power: 6KW

• Gear: 11 teeth

• Rotation Direction: Clockwise (CW)

• Mounting Holes: 3

II. Pre-Installation Preparation

Safety Measures

• Turn off the ignition switch, engage the parking brake, shift the transmission to Neutral (N), and secure the wheels with wheel chocks.

• Wear insulating gloves and goggles; remove jewelry.

• Disconnect the negative (-) battery cable with caution.

Required Tools

• Socket wrench/box-end wrench (matched to starter mounting bolts)

• Torque wrench (37N·m specification)

• Insulated tools

• Cleaning cloth

• Grease (lithium-based or engine oil)

III. Detailed Installation Steps

1. Preparation

• Clean the starter mounting surface to remove oil, rust, and dust, ensuring it is flat and clean.

• Inspect the new starter for no external damage and non-oxidized terminals.

2. Starter Installation

1. Align the starter with the engine mounting position, ensuring proper meshing between the starter gear and the flywheel ring gear.

2. Insert the 3 mounting bolts and hand-tighten them initially.

3. Use a torque wrench to uniformly tighten the bolts in stages to the specified torque (37N·m).

3. Electrical Connections

1. Clean the cable connectors to remove oxides.

2. Connect the main power cable (usually a thick red wire) to the B+ terminal of the solenoid switch and tighten the nut (torque: approx. 9.8N·m).

3. Connect the control wire (thin wire) to the S terminal of the solenoid switch.

4. Finally, reconnect the negative battery cable.

IV. Post-Installation Inspection and Testing

1. Mechanical Inspection

• Verify the starter is securely installed without looseness or wobble.

• Manually rotate the crankshaft to confirm smooth meshing between the starter gear and the flywheel ring gear.

2. Electrical Testing

• Short-circuit the B+ and S terminals of the solenoid switch to observe if the starter gear extends and operates smoothly.

• Start the engine and check if the starter functions normally; the gear should retract quickly after startup.

V. Key Notes

1. Safety First

• Always disconnect the negative battery cable before operation to prevent electric shock and short circuits.

• Strictly prohibit open flames or sparks near the battery to avoid explosion.

• The starter is heavy (approx. 10-15kg); two people should cooperate during removal and installation to prevent injury from dropping.

2. Installation Details

• Gear Clearance Adjustment: After installation, ensure the end face clearance between the drive gear and the flywheel ring gear is 2.5-5mm.

• Excessive clearance: A grinding noise will occur during startup; add shims for adjustment.

• Insufficient clearance: May cause gear jamming; reduce shims.

• Electrical Connections:

• All connectors must be securely fastened to prevent loosening, which may lead to startup failure or ablation.

• Route cables away from high-temperature components and moving parts.

• Error Prevention Points:

• Confirm the correct starter model (24V/6KW/11 teeth); do not use a 12V starter.

• Do not over-tighten the mounting bolts to avoid damaging the housing or engine.

• Distinguish between the main power cable and control wire during wiring; never reverse the connections.

3. Usage and Maintenance Recommendations

• Each startup attempt should not exceed 5 seconds; allow a 10-15 second interval between consecutive starts.

• If startup fails three times in a row, inspect the engine or charging system and resolve the fault before retrying.

• Regularly check the starter mounting bolts and electrical connections to prevent loosening.

• Keep the starter clean and dry; avoid oil contamination and water immersion.

VI. Common Troubleshooting

VII. Summary

References：

I. Original Factory Technical Specifications

1. Hino Official Service Manuals

• Hino 750 Series Service Manual: Provides specific installation steps, torque values, and technical parameters for the starter of 750 Series trucks.

• Hino EF550/EK100 Engine Service Manual: Details the installation requirements and safety precautions for the starters matched with these two engine models.

• Hino Engine General Maintenance Guide: Includes general standards and inspection methods for starter installation.

2. Hino Parts Specification Sheet

• The official starter specifications (24V/6KW/11 teeth/clockwise rotation) are directly sourced from Hino's original factory parts catalog.

• Technical details such as the number of mounting holes (3) and gear parameters comply with Hino's original factory accessory standards.

II. Universal Standards for the Automotive Maintenance Industry

1. Safety Specifications for Starter Installation

• The requirement for power-off operation (disconnecting the negative battery cable first) is derived from the safety standards for automotive electrical maintenance.

• The startup time limit (no more than 5 seconds per attempt, with a 10-15 second interval between consecutive starts) is a universal industry guideline for starter protection.

2. Mechanical Installation Standards

• The torque value (37N·m) complies with automotive fastener standards, ensuring secure connections without damaging the housing.

• The gear clearance adjustment (2.5-5mm) is an industry standard for starter installation, preventing gear grinding or jamming.

III. Technical Documents from Professional Parts Suppliers

1. Starter Manufacturer's Technical Guidelines

• Installation instructions provided by authorized Hino starter suppliers such as Fujian Yida.

• The electrical connection specifications (main power cable connected to the B+ terminal, control wire connected to the S terminal) comply with starter manufacturers' standards.

2. Maintenance Tool and Lubrication Specifications

• The lubrication requirement (using lithium-based grease) refers to the lubrication standards for starter bearings and gears.

• The tool usage specifications (torque wrench, insulated tools) follow the standards for automotive maintenance tool usage.

IV. Comprehensive Compilation Explanation