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Type :
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starter
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Specification :
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24V 4.8KW
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Number of feet :
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9T
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Brand :
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NUOJIN
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Number :
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01179586
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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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Installation of the Deutz 24V 4.8kW starter motor must follow a closed-loop process of "power-off first, model matching, positioning and fastening, weak-current-then-strong-current wiring, no-load/load testing", applicable to Deutz diesel engines (e.g., BF6L913/914, TD226B models, etc.), to ensure powerful starting, no gear grinding, and qualified voltage drop.
Power-off and Safety: Turn off the engine, engage the handbrake, place wheel chocks; disconnect the negative battery terminal and insulate it, prohibit live operation to avoid short circuits and accidental starting.
Model and Appearance Verification: Confirm the specifications of 24V, 4.8kW, and ensure the mounting foot holes, drive gear module/number of teeth, and terminals (30/B+, 50/S) match the original vehicle/engine; the new unit shall be free of cracks, with intact brushes and commutator, and the solenoid switch operates normally.
Tools and Consumables: Socket/wrenches, torque wrench, copper-based anti-seize compound, high-temperature grease, conductive paste, lock washers, cable ties, insulating tape; a hoist or auxiliary support is required if necessary.
Cleaning and Inspection: Clean the flywheel housing mounting surface, bolt holes, and terminals; check the flywheel ring gear for no chipped teeth and the starter motor mounting feet for no deformation; take photos/mark the wiring and bolt positions when removing the old unit, and install in reverse order of removal.
Pre-installation Lubrication: Apply high-temperature grease to the drive gear, splines, shift fork and bushing to ensure smooth return; apply a thin layer of conductive paste to the solenoid switch plunger and contacts to reduce ablation.
Positioning and Fastening: Position the starter motor to align with the mounting holes, insert bolts and hand-tighten; perform cross initial tightening, then final tightening with a torque wrench (common M12～M14 bolts, recommended 65～85 N·m, subject to Deutz engine manual); apply anti-seize compound to bolt threads to avoid high-temperature seizure.
Electrical Connection (Weak Current First, Then Strong Current, Prevent Short Circuit)
Control Wire (Terminal 50/S): Plug in the connector of the start relay/ignition switch, ensure the clip is in place, and keep the wiring harness away from high-temperature and moving parts.
Main Power Wire (Terminal 30/B+): Connect the thick wire from the positive battery terminal, add a lock washer, apply conductive paste after tightening for rust prevention; ensure the negative ground wire is securely fastened with a clean and rust-free ground point, and the voltage drop ≤0.2V.
Re-inspection and Power-on: Check for no wiring harness interference and secure clips; restore the negative battery terminal, measure the battery voltage ≥24.2V; confirm the gear is in neutral and the parking brake is effective before test operation.
No-load Test: Briefly turn on the start switch, the starter motor runs smoothly with no abnormal noise, and the gear returns to position normally; single test duration ≤10 seconds, interval ≥30 seconds.
Load Test: Start the engine, observe powerful starting with no gear grinding, and the gear retracts quickly after starting; record the starting voltage drop ≤0.8V (24V system), otherwise check the battery, wiring harness and ground connection.
Gear Grinding/Meshing Failure: Check ring gear wear, mounting angle, shift fork stroke; adjust the solenoid switch gap or replace the ring gear.
Weak Starting/Low Voltage: Check battery capacity, terminal oxidation, poor grounding; if the main power wire voltage drop is excessive, thicken or shorten the wiring harness.
Solenoid Switch Engagement Abnormal Noise/No Engagement: Check control wire voltage, contact ablation, return spring failure; clean or replace the solenoid switch.
Bolt Loosening/Abnormal Noise: Tighten according to specified torque and re-inspect regularly; add lock washers or thread lock fluid.
Do not idle the starter motor for a long time (single time ≤10 seconds, interval ≥30 seconds) to avoid overheating and burning the coil.
The wiring harness in high-temperature areas requires heat insulation protection, with a distance ≥50mm from exhaust components.
Regularly check the tightness of terminals, gear wear and lubrication status, and handle abnormalities promptly.
Combined with the installation characteristics of the Deutz 24V 4.8kW starter motor and the requirements of high-power starting systems, the following are more detailed core precautions covering safety risk avoidance, installation accuracy control, electrical matching points, and post-sales verification to ensure long-term stable operation after installation:
The negative battery terminal must be disconnected and covered with an insulating cap before installation, and the ignition key must be removed / the start relay plug pulled out (the starting current of a high-power starter motor reaches 300~400A; live operation may cause arc burns or wiring harness burnout); it is strictly forbidden to conduct power-on tests when the starter motor is not fixed to prevent the starter motor from swinging and injuring people.
No-load test run duration per time ≤ 10 seconds, with an interval of ≥ 60 seconds between two tests (the 24V 4.8kW starter motor has a high coil power density; long-term no-load operation may cause insulation layer carbonization and permanent damage to the solenoid switch); before load test runs, the gearbox must be confirmed to be in neutral, the parking brake locked, and no obstacles around the vehicle.
Keep away from the exhaust manifold (temperature can reach above 600℃) during operation, and the wiring harness must be wrapped with high-temperature resistant bellows; do not touch the drive gear by hand when positioning the starter motor (the shift fork rebounds at a high speed and may pinch fingers), and do not pry the starter motor before the mounting bolts are tightened.
Mounting bolts must be coated with copper-based anti-seize compound (the flywheel housing of Deutz engines is made of cast iron; bolts are prone to "seizing" at high temperatures, leading to thread slipping during disassembly);Use a calibrated torque wrench: M12 bolts (65±5 N·m), M14 bolts (85±5 N·m). Loose bolts will cause the starter motor to run off-center (resulting in gear grinding), while over-tightening may crack the mounting feet (the mounting feet of some Deutz models are made of aluminum alloy with high brittleness).
The meshing clearance between the drive gear and the flywheel ring gear must be controlled at 0.8~1.5mm (excessively small clearance will cause gear jamming during cold start, while excessively large clearance results in insufficient meshing depth), which can be measured by prying the shift fork. If the deviation exceeds the limit, adjustment gaskets must be added (only manufacturer-specified gaskets are allowed; do not add iron/copper sheets privately);The starter motor mounting surface must be fully fitted with the flywheel housing (gap ≤0.1mm), otherwise the starter motor axis will be skewed, accelerating the wear of the ring gear and drive gear.
References：
The precautions for installing the Deutz 24V 4.8kW starter motor you referred to are a customized summary compiled by me based on general starter motor installation specifications, maintenance experience of Deutz commercial vehicle/diesel engines, and industry standards, rather than a verbatim excerpt from any single official manual or public document.
Core Framework and Process: Following the closed-loop logic of "power-off — matching — positioning and fastening — electrical connection — testing", it is adapted to the structure and installation space of common Deutz models such as BF6L913/914, TD226B, and TCD2013/2015.
Key Parameters and Values: Torque, clearance, wire diameter, voltage drop, etc., are referenced from Deutz engine maintenance manuals, technical data of starter motor manufacturers, and industry maintenance standards; some values (e.g., bolt torque, meshing clearance) are common values and must be finally confirmed with the official manual of your vehicle/engine model.
Common Problems and Avoidance: Summarized from frontline maintenance cases and after-sales feedback, used for quickly locating on-site faults.
If you need to compare with official documents or obtain authoritative sources, you can search through the following channels:
Deutz Official: Log in to the Deutz AG after-sales portal or authorized dealer platform, download the Workshop Manual for the corresponding engine model, and find the chapter "Starter Motor Replacement/Starting System".
Starter Motor Brands: For brands such as Bosch and Denso, download the installation and maintenance instructions for the corresponding model from their official websites.
Vehicle Manufacturers: If it is a matched complete vehicle, download the maintenance manual from the vehicle manufacturer's after-sales platform and find the content related to starter motor replacement.
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