QDJ251 Starter motor 21020BA005 for Chaochai 6102 6105
Applicable models:Chaochai 6102 6105
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Reference part number:QDJ251 21020BA005
Product Attributes
| Power horsepower : | 24v 6.0kw |
| Number of feet : | 11T |
| Size : | 44*24*20 single unit inner box |
| Weight : | net weight：8.65KG gross weight：9.2KG |
| Packaging : | Neutral kraft paper packaging |
| Spot/Pre sale : | Spot goods |
| Warranty : | 1 year |
| Product number : |
Product Details
| Type : | ENGINE STARTER |
| Specification : | 24v 6.0KW |
| Number of feet : | 11T |
| Brand : | nuojin |
| Number : | QDJ251 21020BA005 |
| Quality : | RENOVATE |
| Delivery time : | 10 day |
Installation Method of 24V Starter for Chaochai 6102/6105 Engines
This installation method applies to the 24V electromagnetic meshing starter matched with Chaochai 6102 and 6105 series diesel engines. Prior to installation, confirm that the starter model is fully matched with the number of teeth of the engine flywheel ring gear and the mounting hole positions. The core principles of clean alignment, torque compliance, firm wiring and gap specification shall be followed, along with supporting safe operation specifications, to ensure proper meshing and operation of the starter after installation.
I. Pre-installation Preparation
1. Tools and Consumables
Special tools: Socket wrenches (for mounting bolts and wiring terminals), torque wrenches, crowbars (for auxiliary alignment), feeler gauges (for meshing gap detection);Consumables: High-temperature resistant engine sealant, lock washers/spring washers, copper-based grease (for flywheel ring gear and starter drive gear), sandpaper/wire brushes (for cleaning contact surfaces);Auxiliary supplies: Insulating tape, cable ties (for wire arrangement).
2. Safety and Preliminary Inspection
Disconnect the negative terminal of the vehicle's 24V main power supply and remove the battery negative wiring to prevent electrical component burnout due to short circuit during installation;Inspect the starter body: No wear, deformation or jamming of the drive gear, flexible action of the electromagnetic switch, no oxidation or damage to the terminal posts, and no cracks on the motor housing;Inspect the mounting surface at the engine flywheel end: No broken teeth or severe wear on the flywheel ring gear, no deformation or thread slipping of the mounting holes on the starter mounting bracket/flywheel housing, and clean up oil, rust and sealant residue on the mounting surface;Confirm the tooth side gap and meshing depth between the flywheel ring gear and the starter drive gear. New parts are matched by default, and used parts shall be inspected in advance (gaskets shall be adjusted if the gap is abnormal).
3. Accessory Verification
Core accessories for the installation of Chaochai 6102/6105 starter: Mounting bolts (2-3 pieces, high-strength grade 8.8 and above), positioning pins/gaskets (for meshing gap adjustment, factory standard configuration), wiring terminals (thick main terminal + thin control terminal). Ensure that the accessories are of original factory or adapted specifications, and do not replace high-strength mounting bolts with ordinary bolts.
II. Core Installation Steps (Universal for 6102/6105 with slight difference in hole positions)
Step 1: Cleaning and Pre-lubrication
Polish the starter mounting flange surface and the engine flywheel housing mounting contact surface with sandpaper/wire brushes to ensure no oil, rust and tight fit without gaps;Evenly apply copper-based grease to the tooth surfaces of the flywheel ring gear and the starter drive gear (butter is prohibited as it melts and forms carbon deposits at high temperatures). The application amount shall cover 1/3 of the tooth surface to prevent dry friction during meshing;Apply a small amount of thread lock to the threads of the starter mounting bolts (or install spring washers) to improve the fastening and anti-loosening effect.
Step 2: Starter Alignment and Preliminary Fixation
Cooperate by one or two persons: Align the drive gear end of the starter with the flywheel ring gear, slowly push it into the mounting position to make the starter flange surface fully fit with the flywheel housing mounting surface, and ensure accurate alignment of the positioning pin holes (if any). Forcible knocking on the starter body is prohibited (which may damage internal bearings and electromagnetic switches);Insert 1-2 mounting bolts and manually tighten them to preliminary fixation (the bolt screwing depth ≥ 2/3 of the thread length). At this time, the starter can slightly shake to facilitate subsequent meshing gap adjustment.
Step 3: Meshing Gap Detection and Adjustment (Key Step)
Standard meshing gap of Chaochai 6102/6105 starter: Tooth side gap 0.2-0.5mm and meshing depth 10-15mm between the drive gear and the flywheel ring gear, which shall be detected with a feeler gauge. Abnormal gaps shall be adjusted by increasing or decreasing gaskets on the mounting surface:If the gap is too small (< 0.2mm): The drive gear is prone to tooth jamming and locking. Install thin gaskets (0.1-0.2mm per piece) between the starter flange surface and the flywheel housing, and adjust step by step until the standard is met;If the gap is too large (> 0.5mm): Loose meshing and slipping may occur. Remove the original gaskets (if any) or replace with thinner positioning gaskets;After the gap meets the standard, screw in all mounting bolts in sequence to ensure uniform stress on the bolts without deflection.
Step 4: Tightening of Mounting Bolts (Torque Must Comply with Standard)
Tighten the mounting bolts with a torque wrench in accordance with the diagonal tightening principle. The standard torque of mounting bolts for Chaochai 6102/6105 starter is 80-100N·m. Forcible tightening with a pneumatic wrench is prohibited (which may cause bolt thread slipping and flywheel housing cracking);After tightening, inspect the starter body: No looseness or shaking, no contact or jamming between the drive gear and the flywheel ring gear, and the drive gear can flexibly return when manually toggled.
Step 5: Wiring (24V System, Positive and Negative Poles Are Strictly Prohibited to Be Reversed)
Wiring shall follow the principle of connecting the main power line first, then the control signal line, and finally the ground. All wiring terminals must be equipped with lock washers and fastened without looseness or oxidation:Main power line connection: Take a vehicle-specific thick copper core wire (≥16mm², for 24V starter), connect one end to the starter's thick terminal post (marked "+"/BATT, main power post) and the other end to the battery positive pole. Fasten the terminal with a nut (torque 30-40N·m) and wrap it with insulating tape for protection;Control signal line connection: Take a thin copper core wire (≥2.5mm²), connect one end to the starter's thin terminal post (marked "S"/SOL, electromagnetic switch control post) and the other end to the vehicle's ignition switch/starting relay control end, ensuring no damage or grounding of the line;Ground wire confirmation: The contact surface between the starter flange surface and the flywheel housing is the main ground. If the contact surface is in poor contact, an additional ground wire (≥10mm²) shall be installed, with one end connected to the starter housing and the other end to the engine block/frame, ensuring the ground resistance < 0.1Ω;Wire arrangement: Fix the power line and control signal line on the engine body with cable ties, keep them away from high-temperature components (exhaust pipe, turbocharger) and moving components (fan, belt), and reserve a certain amount of movement to prevent line abrasion due to vibration.
Step 6: Sealing Treatment
Evenly apply high-temperature resistant engine sealant to the joint gap between the starter flange surface and the flywheel housing (sealant application width 2-3mm) to prevent engine oil and coolant leakage, as well as dust and muddy water from entering the meshing part.
References：
The provided installation method and precautions constitute an integrated technical document, not a direct excerpt from a single public manual. It is compiled on the basis of original factory technical specifications, industry national standards and frontline maintenance practices. The complete sources and basis are as follows:
I. Sources of Core Technical Parameters and Model-Specific Content
1. Official Original Factory Basis of Chaochai
Source: Original Factory Maintenance Manual (Service Station Internal Version) for 6102/6105 series diesel engines, Dongfeng Chaoyang Diesel Engine Co., Ltd.Corresponding Content:
Requirements for differences in mounting hole positions, flange dimensions and bolt specifications between 6102 and 6105 models
Torque of starter mounting bolts: 80-100N·m
Meshing gap between flywheel ring gear and drive gear: 0.2-0.5mm; Meshing depth: 10-15mm
Model-specific layout requirements including left/right engine mounting positions and avoidance of fuel pumps/oil pipes
Note: This manual is exclusively for authorized Chaochai service stations and not available for public sale, with no complete public electronic version online. All parameters are derived from the practical operation specifications of service stations and original factory technical disclosure documents.
2. National Industry Standards (Mandatory/Recommended)
- QC/T 731-2005 Technical Specifications for Automobile Starters (replacing the old version QC/T 29064-1992; the previously marked standard number 29064 refers to the obsolete version, and the current valid one is QC/T 731-2005)Source: Issued by the National Development and Reform Commission, under the jurisdiction of the National Technical Committee for Automobile Standardization, drafted by Changsha Automobile Electrical Apparatus Research Institute.Corresponding Content: General technical requirements for 24V starters such as wiring specifications, grounding requirements, no-load test run time limit, gear meshing accuracy, and insulation and protection class.
- General Specification for Installation of Starting System of Automotive Diesel EnginesCorresponding Content: General installation processes including power-off operation, wire gauge selection for circuits, anti-loosening and sealing, high-temperature avoidance and vibration protection.
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