High Performance Diesel Engine Parts ISF3.8 Starter Motor For Foton Cummins 5585086 5319202 4937470 5263841 5268413
Applicable models:Foton Cummins
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Reference part number: 5585086 5319202 4937470 5263841 5268413
Product Attributes
| Power horsepower : | 24V 3.6KW |
| Number of feet : | 10T |
| Size : | 44*24*19 cm single unit inner box |
| Weight : | net weight：7KG |
| Packaging : | Neutral kraft paper packaging |
| Spot/Pre sale : | Spot goods |
| Warranty : | 1 year |
| Product number : |
Product Details
| Type : | Engine starter |
| Specification : | 24V 3.6KW |
| Number of feet : | 10T |
| Brand : | nuojin |
| Number : | 5585086 5319202 |
| Quality : | Remanufacture |
| Delivery time : | 10DAY |
Installation Specification for Foton Cummins 24V Starter Motor
The installation of a Foton Cummins 24V starter motor shall follow the core procedure: Safety Power Disconnection → Cleaning and Positioning → Standardized Fastening → Correct Wiring → Test and Verification. Priority controls include mounting surface cleanliness, bolt torque, and wiring reliability. This specification applies to mainstream models such as ISF2.8/3.8 and ISG11/12. The structured installation specifications and key points are as follows.
I. Pre‑installation Preparation
1. Tools and Spare Parts
| Category | List | Notes |
|---|---|---|
| Tools | Socket wrenches (12–18 mm), torque wrench (0–500 N·m), multimeter, wire brush, sandpaper, cleaning cloths, insulating tape | The torque wrench must be calibrated to ensure accurate readings. |
| Spare Parts | Model‑matched 24V starter motor, mounting bolts (M12×1.75, 2–3 pcs), gaskets, lock nuts, high‑temperature resistant power cable (≥70 mm²), control cable (≥2.5 mm²), wiring terminals, fuse (200 A) | Bolts must conform to original factory specifications; mixing of non‑standard parts is prohibited. |
| Inspection Items | Confirm starter model compatibility; check for intact appearance, non‑jamming drive gear, and proper solenoid operation. Verify the flywheel ring gear has no broken teeth and the mounting surface is flat and crack‑free. | Rotate the drive gear by hand to confirm proper function of the one‑way clutch. |
2. Safety Prerequisites
Shut down the engine, remove the ignition key, and disconnect the negative terminal of the 24V battery to prevent short circuits and sparks.
Allow the engine to cool to room temperature to avoid scalding. Clean up oil contamination and debris in the installation area.
Mark the positions of the old starter wiring harness and take photos for reference during reassembly.
II. Standard Installation Procedure
Step 1: Remove the Old Starter Motor (Replacement Scenario)
Disconnect the engine wiring harness: first remove the thin control wire from the solenoid switch, then the thick main power cable, and mark all connections clearly.Loosen the 2–3 mounting bolts in a diagonal sequence, then remove the starter motor smoothly to avoid impact damage to the drive gear.Clean the mounting surface: use a wire brush and sandpaper to clean the engine mounting surface and threaded holes, removing rust and oil contamination. Retap the threads with a tap if necessary to repair damage.
Step 2: Position and Install the Starter Motor Assembly
Pre‑positioning: Align the drive gear end of the new starter with the flywheel ring gear, ensuring the gear and ring gear are parallel and aligned, and that the starter flange fits tightly against the mounting surface.Install the mounting bolts: insert the bolts and tighten them lightly by hand, ensuring the starter has no looseness or wobble.Torque fastening: Tighten the bolts gradually in diagonal passes. The torque for M12 bolts is 215–300 N·m (subject to the model‑specific factory manual), to prevent housing cracking or loosening.
Step 3: Electrical Wiring (Critical for 24V Systems)
| Terminal | Connection Target | Specification |
|---|---|---|
| B+ (Main Power) | Positive terminal of the battery (cable ≥70 mm²) | A 200 A fuse must be series‑connected in the circuit. Terminals shall be securely crimped with intact insulation sleeves. |
| S (Control) | Output terminal of the starter relay (cable ≥2.5 mm²) | Avoid loose connections. Secure the wiring harness with cable ties and route it away from high‑temperature components. |
| GND (Ground) | Engine cylinder block / vehicle frame | Ground resistance shall be less than 0.5 Ω. Grind the contact surface to remove paint and coatings. |
Wiring sequence: Connect B+ first, then S, then GND. Ensure all terminals are tight and the wiring harness has no interference.Insulation protection: Cover exposed terminals with insulating tape to prevent short circuits.
Step 4: Testing and Verification
Reconnect the negative terminal of the battery. Turn the ignition switch to the “ON” position and confirm there are no abnormal warning lights on the dashboard.Start‑up test: Each cranking duration shall not exceed 5 seconds, with an interval of at least 30 seconds between consecutive attempts. Observe that the starter runs smoothly without abnormal noise, and that the flywheel drives the engine to start normally.Voltage check: Use a multimeter to measure the voltage at the B+ terminal during cranking; a reading ≥22 V is normal. Measure the charging voltage at idle; a stable range of 27–29 V is normal.Re‑torque bolts: After shutting down the engine, re‑tighten all mounting bolts to the specified torque, then clean up tools and the work area.
Complete Precautions for Installation, Wiring, Commissioning and Long‑term Use of Foton Cummins 24V Starter Motor
This document summarizes complete precautions covering the whole process of installation, wiring, commissioning and long‑term use of Foton Cummins 24V starter motors. They are categorized by safety operation, mechanical installation, electrical wiring, test acceptance and routine maintenance. All items are critical points that are most prone to problems and equipment damage in practical operation, for direct on‑site reference and implementation.
I. Safety Operation (Top Priority)
Full Power Disconnection
Disconnect the negative terminal of the 24V battery before the entire process of installation, removal and wiring. Live working is strictly prohibited. The 24V system carries extremely high current; a short circuit will instantly produce intense arcing, erode terminals, melt wiring harnesses and even cause fire. It is absolutely forbidden to plug or unplug starter circuits while the engine is running or the ignition switch is on.
High Temperature and Mechanical Protection
Wait for the engine to cool down completely before operation, as high‑temperature areas such as the exhaust pipe and cylinder block can easily cause scalding. During disassembly and assembly, avoid sharp and high‑temperature components including the flywheel housing, drive shaft and exhaust pipe to prevent impact and scratches.
Prohibition of Illegal Start Tests
Do not perform forced test runs by directly shorting the B+ and S terminals of the starter, especially when the starter is not fully secured or protective components are not reinstalled. This can easily cause gear grinding and the starter being thrown out, resulting in personal injury.The duration of a single cranking must not exceed 5 seconds, and consecutive cranking attempts must be separated by an interval of at least 30 seconds to prevent overheating and burnout of the starter coil.
II. Core Mechanical Installation Precautions
Mounting Surface and Gear Meshing Requirements
The starter flange and the engine flywheel housing mounting surface must be thoroughly cleaned to remove oil contamination, paint, rust and burrs, ensuring 90% contact. Gaps will lead to vibration, loose bolts and housing cracking.The drive gear and flywheel ring gear must be coaxial and parallel. Forcible installation by hammering or prying is strictly prohibited, otherwise it will cause broken ring gear teeth, damage to starter bearings and abnormal noise during starting.Before installation, rotate the starter drive gear by hand to confirm that the one‑way clutch slides smoothly without jamming or excessive clearance. Defective components must be replaced in advance; faulty installation is not allowed.
Bolt Fastening Specifications
Only original‑specification bolts, spring washers and flat washers shall be used. Mixing bolts of different strength grades and thread specifications is prohibited.Fastening must be carried out by gradual tightening in a diagonal sequence. Tightening a single bolt fully at one time is strictly prohibited to avoid uneven stress and deformation of the flange.
References：
The content of installation precautions for the Foton Cummins 24V starter motor is integrated and compiled from official technical documents, industry standards and field practical experience, rather than being directly quoted from a single original text. The specific sources and authoritative references are as follows.
I. Core Official Technical Documents (Basic References)
Original Foton Cummins Factory Repair Manuals
ISF2.8/3.8 Series Engine Service Manual: Specifies the starter mounting bolt specification (M12×1.75), torque parameters (215–250 N·m), mounting surface cleaning requirements, terminal definitions and wiring harness specifications.
ISG11/12 Series Engine Service Manual: Defines the dual‑bolt fixing method for top‑mounted starters, torque range (250–300 N·m) and hoisting and positioning requirements.
Cummins 24V Starting System Standard
Cummins 24V Starter Installation Specification: Standardizes electrical requirements including main power cable cross‑section (≥70 mm²), control cable cross‑section (≥2.5 mm²), 200A fuse selection, and grounding resistance (< 0.5 Ω).
Foton Cummins Parts Catalog
Specifies original factory specifications for starter mounting bolts, gaskets, lock nuts and other spare parts; mixing non‑standard parts is strictly prohibited.
Cummins Global Technical Service Bulletins (TSB)
Stipulates thermal protection requirements, including a single cranking time no longer than 5 seconds and an interval of at least 30 seconds between consecutive start attempts, as well as anti‑reverse polarity wiring specifications for the solenoid switch.
II. Industry Standards and General Specifications (Compliance References)
National Standard Technical Specifications for Installation of Electrical Equipment on Agricultural Machinery (GB/T 30531–2014): Specifies safety operations, wiring harness protection and grounding reliability requirements for electrical component installation.
General Specifications for Automotive Electrical Industry: Cover short‑circuit protection for 24V systems, wiring harness thermal insulation (maintaining a distance of at least 50 mm from high‑temperature components), terminal crimping and insulation treatment standards.
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