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Type :
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Engine starter
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Specification :
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24V 7.5KW
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Number of feet :
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12T
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Brand :
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nuojin
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Number :
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600-813-3632 600-812-6632
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Quality :
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Regeneration
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Delivery time :
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10DAY
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The Komatsu 24V 7.5KW starter is mainly compatible with heavy-duty equipment such as its excavators. Installation must adhere to principles including power-off protection, precise alignment, and standardized wiring to avoid damaging the starter or equipment circuits. The specific steps are as follows:
Wear safety goggles and non-slip gloves. Prepare tools such as a socket wrench, screwdriver, wire brush, anti-rust lubricant, and air compressor spray gun. Then turn off the equipment's ignition switch, disconnect the negative battery terminal first, followed by the positive terminal, to prevent short circuits that could burn out electronic components during installation.
Verify that the new starter model is compatible, with no cracks on the housing, no damage to the gears, and proper contact between the brushes and commutator. Next, clean the mounting surface on the engine flywheel housing to remove oil, rust, and debris; simultaneously inspect the flywheel ring gear. If severe wear or damage is detected, repair or replace it first to avoid affecting starter gear engagement. Additionally, apply a small amount of grease to the transmission case bushing, armature shaft, and overrunning clutch spiral splines.
Fit the starter firmly against the mounting surface, align it with the bolt holes on the housing, and manually thread 2-3 mounting bolts to secure it initially, preventing bolt misalignment or thread damage.
Tighten the bolts to the torque specified in the equipment manual using a torque wrench (typically 30-50N・m for heavy-duty equipment starters; refer to the specific Komatsu model manual for exact values). Ensure the starter is securely fastened with no looseness or wobble.
First, connect the main power terminal on the starter solenoid, fasten the positive battery cable to the corresponding terminal, and install flat washers and lock washers to prevent loosening. Then connect the control wiring connector, ensuring it is fully inserted and the locking clip is engaged to avoid poor contact.
After connecting the wiring, arrange the cable routing to avoid contact with high-temperature engine components or rotating parts, preventing cable abrasion or burnout.
Reconnect the positive battery terminal first, followed by the negative terminal, ensuring secure connections with no oxidation.
Start the equipment for a no-load test: observe if the starter operates smoothly, check for abnormal noise, and confirm proper gear engagement. For 24V starters, perform a 12V no-load test first, then switch to 24V to avoid overload damage. If the starter operates normally, installation is complete. If there is no response, gear jamming, or other issues, immediately disconnect the power and inspect the wiring or mounting position.
Throughout the installation process, the positive and negative battery terminals must be disconnected first (prioritize the negative terminal). After all mechanical fastenings and wiring connections are completed, restore power in the order of "positive terminal → negative terminal". It is strictly prohibited to wire or adjust components with power on, to prevent short circuits that may burn out the starter coil, equipment ECU, and other electronic components.
Must wear safety goggles (to prevent debris from splashing into the eyes) and non-slip insulating gloves (to avoid slipping due to oil on hands or electric shock). The work area should be away from flammable and explosive materials, and installation is prohibited when the engine is at high temperature.
Do not directly touch the starter solenoid terminals with metal tools, and prohibit testing the starter by short-circuiting (which may easily cause coil overheating and burnout). Do not knock or strike components forcibly during installation. If gears, shafts, or other parts fit too tightly, use special tools for auxiliary alignment to prevent damage to the gear tooth surface, armature shaft, or housing.
Confirm that the rated parameters of the new starter (24V voltage, 7.5KW power) are fully compatible with the Komatsu equipment model. Check that the starter housing has no cracks, the overrunning clutch gear has no missing teeth/wear, the brushes have no excessive wear (replace if wear exceeds 3mm), and the wiring terminals have no oxidation or rust.
Thoroughly clean oil stains, rust, and sealant residues from the mounting surface of the engine flywheel housing to ensure the starter fits flat (avoid uneven stress after installation). Focus on inspecting the flywheel ring gear: if the tooth surface wear exceeds 1/3, or there are broken teeth or chipped corners, replace the ring gear before installing the starter. Otherwise, it may lead to poor gear meshing, abnormal noise, or even jamming.
Apply a small amount of high-temperature lithium-based grease to the starter armature shaft splines, overrunning clutch, and transmission case bushing (avoid excessive application to prevent oil splashing onto the clutch or flywheel). If there is a gasket on the mounting surface, replace it with a new one and apply sealant evenly to prevent oil leakage.
Use a torque wrench to tighten the mounting bolts to the torque specified in the Komatsu equipment manual (typically 30-50N・m for heavy-duty equipment; refer to the specific model manual for exact values). Install flat washers and lock washers on the bolts, and tighten them evenly in steps (avoid excessive stress on a single bolt causing housing deformation). After tightening, check that the starter is secure with no looseness or wobble.
The main power terminal (thick wire terminal) must be securely fastened. Cable joints should be crimped firmly with a crimping tool to avoid poor contact and overheating (a small amount of conductive paste can be applied to prevent oxidation).
The control wiring connector must be fully inserted and the locking clip engaged. Forced insertion or removal is strictly prohibited. If marks were made on the wires when removing the old starter, wire the new starter strictly according to the marks (wrong wiring in a 24V system may directly burn out the starter or control module).
Arrange the cable routing to avoid contact with high-temperature/rotating components such as the engine exhaust pipe and fan. The cable bending radius should not be too small to prevent cable wear and short circuits caused by long-term vibration.
No-Load Test: After restoring power, start the equipment briefly (each start time ≤5 seconds, interval between two starts ≥30 seconds). Observe if the starter operates smoothly with no metal abnormal noise, and if the gears mesh smoothly without jamming.
Load Test: After the no-load test is normal, perform an actual start test to confirm that the engine starts quickly with no delay. If problems such as weak starter power, repeated gear grinding, or no start response occur, immediately disconnect the power and troubleshoot (prioritize checking if the wiring is secure, the mounting position is offset, or the battery voltage is sufficient).
References：
The core installation precautions for the Komatsu 24V 7.5KW starter you inquired about are not derived from a specific original Komatsu official manual or single authoritative document. Instead, they are a comprehensive summary integrating general installation specifications for heavy-duty equipment starters, structural characteristics of Komatsu heavy machinery, and practical maintenance experience within the industry.
Specifically, the core logic and relevant reference directions for the content are as follows:
Whether for starters of automobiles or heavy-duty equipment such as Komatsu excavators, core processes during installation—including power-off protection, component verification, standardized wiring, and post-installation testing—are universal guidelines. For example, key points such as disconnecting the negative battery terminal before installation, tightening fixing bolts to the specified torque, and avoiding prolonged no-load operation during testing are all industry-wide universal precautions for starter installation.
This starter is compatible with Komatsu excavators and other heavy-duty equipment. The content takes into account the installation scenarios of starters for heavy-duty equipment. Details such as emphasizing the inspection of the flywheel ring gear, special testing methods for the 24V voltage system, and the requirement for cables to be kept away from high-temperature and rotating engine components are supplementary details tailored to the operating conditions and structural characteristics of Komatsu heavy machinery.
Precautions such as prohibiting forced knocking of components, connecting the main power supply before control wires during wiring, and pre-checking the battery voltage are derived from common problems (e.g., starter damage and circuit short circuits) caused by improper operation during maintenance. These summarized practical pitfall-avoidance points help prevent issues such as gear jamming and weak starting after installation.
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