Product Overview

The 228000-7902 is a brand-new starter motor delivering 24V output at 4.5KW with a 10-tooth drive gear, engineered for Cummins, Case, Hyundai construction equipment and Liugong excavators PC200-6 with the S6D102 engine. This unit, cross-numbered as 3934119, 3957593 and Lester 18548, matches the original starting-system specification for the PC200-6 construction equipment platform.

This starter motor is stocked in-house with a 1-year warranty and 10-day dispatch lead-time. The factory-correct 24V 4.5KW specification ensures reliable cranking performance for PC200-6 excavator applications.

Key physical specs: net weight 7.8 kg, gross weight 8.4 kg, overall dimensions 440 x 240 x 190 mm, supplied inside neutral kraft inner carton.

The PC200-6 S6D102 Construction Equipment Starting Platform

Komatsu PC200-6 excavators with the S6D102 engine, plus compatible Cummins, Case, Hyundai construction equipment and Liugong excavators, use a 24V starting system with 10T starter motors. The starter numbering for this family includes 228000-7900, 228000-7901 and 228000-7902 (the 228000 series), plus the OEM numbers 3934119 and 3957593. The Lester interchange reference number for this family is 18548, and the manufacturer cross-reference numbers 600-863-4110 and 228000-4992 are mentioned in the original installation guide as model-verification references.

It is critical to verify the voltage, power rating and tooth count on your old starter: this unit is rated at 24V 4.5KW with a 10T drive gear. Starters with a different voltage, power rating, tooth count or mounting pattern are not interchangeable with this unit. The 10T drive gear is a key identification point for the PC200-6 unit, so count the teeth on your old starter pinion carefully.

Confirm the mounting flange pattern, terminal positions and bolt spacing against your original starter before ordering. Always cross-check the OE numbers stamped on your old unit, including the 228000-7902 family, before placing an order.

Technical Specifications

Compatibility and Cross Reference

According to the original product page, this starter motor fits Cummins, Case, Hyundai construction equipment and Liugong excavators PC200-6 with the S6D102 engine. The original page does not publish a detailed fitment table, so do not rely on the machine name alone for fitment validation; always compare the original part number, mounting holes, tooth count and connector configuration before ordering.

Multiple OEM numbers appear across production batches and regional market specifications for this same starter family. If your original unit bears one of the listed cross-reference numbers, 228000-7902 serves as a direct drop-in replacement.

What to Look for in a Replacement

Follow these five verification steps before placing your order to avoid wrong-part returns:

• 1. Check the voltage and power rating on your old starter: confirm it is a 24V 4.5KW unit for the S6D102 engine. Other ratings are not interchangeable.

• 2. Check the tooth count on your old starter: confirm it is a 10T drive gear. Starters with a different tooth count are not interchangeable.

• 3. Confirm the machine is a PC200-6 or a compatible Cummins, Case, Hyundai or Liugong excavator with the S6D102 engine. Other machines may use different starter assemblies.

• 4. Compare the mounting holes, flange pattern and connector configuration with your original starter, and match OE numbers including the 228000-7902 family and Lester 18548.

• 5. Weight cross-check: genuine matching unit weighs approximately 7.8 kg net; significant weight difference indicates wrong assembly.

Application Scenarios

• Construction equipment repair shops servicing PC200-6 excavators with failed starting systems.

• Excavator and heavy-machinery fleet maintenance teams replacing worn 24V starters.

• Auto parts retailers and distributors stocking construction-equipment starters for the aftermarket.

• Machine owners and workshop teams replacing worn starters with a factory-spec new unit.

• Exporters supplying construction-equipment starters to global markets.

FAQ

Q: Which machines does this starter motor fit?
A: It fits Cummins, Case, Hyundai construction equipment and Liugong excavators PC200-6 with the S6D102 engine. Confirm your exact machine model, year and OE number before ordering, and check that your old starter is a 24V 4.5KW 10T unit.

Q: My old starter shows OE number 3934119 or 3957593, will 228000-7902 work?
A: Yes. These numbers belong to the same starter family for the PC200-6 S6D102 platform, differing only by production revision and market specification. It serves as a direct replacement.

Q: What does Lester 18548 mean?
A: Lester 18548 is the Lester interchange reference number for this starter family, widely used in the American aftermarket to cross-reference starter motors. It confirms the same application family as 228000-7902.

Q: My old starter has 11 teeth, will this 10T unit fit?
A: No. The tooth count must match: this unit has a 10T drive gear, and a starter with a different tooth count is not interchangeable. Confirm the tooth count of your old starter before ordering.

Q: What is the correct charging voltage after installation?
A: A healthy 24V charging system should regulate at approximately 27-29V at the battery terminals with the engine running. If the voltage is out of range, check the alternator, regulator and wiring before further testing.

Q: What is your warranty and lead-time?
A: Goods are in stock with a 10-day dispatch lead-time. A 1-year warranty applies from installation date; warranty excludes damage caused by mis-installation, incorrect wiring, water ingress, short circuit or physical damage.

In Practice

The original product page provides a complete installation guide for this 24V 4.5KW S6D102 starter, covering the installation method, installation precautions, commissioning and troubleshooting. The full content is absorbed below as published on the original page.

Safety Preparation

1. Disconnect the negative battery cable to prevent short circuit; turn off the key switch and remove the key.

2. Prepare tools: socket wrench (including extension rod), torque wrench, wire brush, cleaning cloth, thread locking adhesive (e.g., Loctite 243), lock washer.

3. Check the matching of the new starter model: 24V, 4.5kW, suitable for the S6D102 engine. Refer to part numbers 600-863-4110 or 228000-4992.

4. Wear safety goggles and gloves; clean the work area to prevent tools or parts from falling into the flywheel housing.

Removal of the Old Starter

1. Disconnect the power cable (thick wire, B+ terminal) and control wire (thin wire, S terminal) of the solenoid switch, and make clear marks.

2. Remove the starter mounting bolts (usually 2-3 pieces of M12), loosen them in a diagonal sequence gradually. Hold the starter securely and take it out smoothly to avoid collision with the drive gear.

3. Inspect the flywheel ring gear for tooth chipping or wear; replace it if necessary. Clean oil stains and rust on the engine mounting surface.

Installation of the New Starter

1. Cleaning and Positioning: Clean the starter flange and engine mounting surface thoroughly to ensure a tight fit without gaps. Align the drive gear end of the starter with the flywheel ring gear, push it into place gently to guarantee coaxiality.

2. Pre-installation of Bolts: Apply a small amount of thread locking adhesive to the bolt threads, pre-screw the bolts into the starter mounting holes without fully tightening them.

3. Tightening of Bolts: Tighten the bolts gradually in a diagonal sequence. Follow the torque specifications for different models:

4. Wiring Connection: Connect the power cable to the B+ terminal with a torque of 12±2 N.m; connect the control wire to the S terminal to ensure a firm connection without looseness.

5. Return Check: Manually toggle the drive gear to confirm that it can return freely without jamming.

Commissioning and Acceptance

1. Reconnect the negative battery cable, turn the key switch to ON position, and check that the instrument panel is powered normally.

2. Start-up Test: Each single start-up shall not exceed 5 seconds; the interval between consecutive start-ups shall be 10-15 seconds. Listen for abnormal noises to ensure smooth gear meshing without slipping or abnormal sounds.

3. After shutting down the engine, check again that the drive gear has fully returned without dragging. Inspect the wiring connections for no looseness or overheating.

4. Clean up tools, tidy the work area, and complete the installation record.

Key Specifications

Installation Precautions

1. Power-off and lockout: Disconnect the negative battery cable first and hang a warning tag; turn the key switch to OFF position and remove the key to prevent accidental startup. The 24V system has a high risk of short circuit, so live operation is strictly prohibited.

2. PPE: Wear safety goggles, oil-resistant gloves and non-slip shoes. Ensure no flammable materials are present in the work area. Arrange tools and parts in an orderly manner to prevent them from falling into the flywheel housing.

3. Model verification: Confirm the starter specifications: 24V, 4.5kW, suitable for the S6D102 engine. Refer to part numbers 600-863-4110 or 228000-4992. Check that the new starter housing is free of cracks and the drive gear is undamaged.

4. Tools: Prepare a torque wrench (accuracy ±3%), socket wrench (including extension rod), wire brush, cleaning cloth, thread locking adhesive (e.g., Loctite 243) and lock washers. The use of electric impact wrenches to tighten mounting bolts is strictly prohibited.

5. Mounting surface and positioning: Thoroughly remove oil stains, rust and residual old gaskets from the engine flywheel housing mounting surface and starter flange to ensure a tight fit without gaps. Align the drive gear end with the flywheel ring gear, push it into place gently, and manually rotate the flywheel to confirm there is no interference. Inspect the flywheel ring gear for tooth chipping and wear (replace if tooth thickness is less than or equal to 2/3 of the original thickness or end face runout exceeds 0.3mm). The meshing clearance should be 0.5-1.5mm, and the axial distance should be 3-5mm (subject to the model manual).

6. Bolt specifications: The mounting bolts are usually 2-3 pieces of M12×1.75 with matching length, intact threads and no slipping. Apply a small amount of thread locking adhesive and pre-tighten the bolts in place without full tightening. Tighten the bolts gradually in a diagonal sequence: 110-137 N.m for Komatsu PC200-6 (S6D102); 25-30 N.m for universal M12 bolts. Full tightening in one step or over-torquing is strictly prohibited to prevent housing deformation. Install lock washers or use split pins/locking wires for anti-loosening.

7. Wiring connection: Connect the control wire (thin wire, S terminal) first, then the power cable (thick wire, B+ terminal). Confirm the key switch is in OFF position before wiring. Tighten the B+ terminal to a torque of 12±2 N.m. Ensure the S terminal is firmly connected, with no ablation on terminals and no damage to wire harnesses. The ground wire must be reliably connected, with a grounding resistance of less than 0.1 ohm. Route the wire harness away from high-temperature areas (e.g., exhaust manifold) and moving parts (e.g., fan, belt). Secure it with cable ties and reserve allowance for thermal expansion and contraction.

8. Drive gear and return: Never strike the drive gear or one-way clutch to avoid damaging the internal pawl mechanism. Manually toggle the gear to confirm it can return freely without jamming or dragging. After installation, rotate the flywheel to confirm smooth meshing between the drive gear and ring gear with no tooth jamming or abnormal noise.

Common Troubleshooting

After installation, it is recommended to start the engine continuously for 3-5 times and observe the working status of the starter to ensure that there is no abnormality.

References

The original product page publishes the following references for this starter motor, reproduced as stated on the original page:

I. Core Manuals and Original Factory Specifications

II. Torque and Key Parameter Basis

III. Safety and Operation Specification Sources

Note: The reference tables above are reproduced as published on the original product page. For vehicle-specific torque values, always refer to the corresponding factory service manual.

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