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Type :
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Starter Motor
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Specification :
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24V 7.5KW
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Number of feet :
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11T
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Brand :
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NUOJIN
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Number :
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300516-00075:3 65.26201-7074D
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Quality :
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Remanufacture
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Delivery time :
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10DAY
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Doosan DE12TIS (DH370/DH500-7) 24V Starter Installation Method
(General Specification for Maintenance & Assembly)
This specification applies to 24V starters (24V/6.0kW/11 teeth, part numbers 65.26201-7070, 300516-00055 series) for Doosan DE12TIS engines fitted to DH370 and DH500-7 models. Based on original factory service manuals and construction machinery assembly standards, it covers the complete process of safety preparation, removal, installation, torque specifications, wiring, meshing clearance, and testing, and can be directly used in technical service documents and on-site operations.
1. Pre-installation Preparation (Safety + Verification + Cleaning + Tools)
1.1 Safety Power Disconnection (Mandatory Requirement)
Park the excavator securely, apply the travel brake lock, shut off the engine completely and allow it to cool to ambient temperature, and turn off the main power switch.
Disconnect the negative terminal of the 24V battery first, then the positive terminal, and remove all electrical connections to the starter to prevent short circuits, sparks, and burning of the solenoid switch and wiring harness. Wear insulated gloves throughout the operation. It is strictly prohibited to disassemble or assemble the starter B+ main power terminal with power connected.
Clean up oil and debris around the engine flywheel housing, and provide fire and collision protection for the work area.
1.2 Model and Component Verification
Select a genuine or certified Doosan 24V starter. Verify parameters: voltage (24V), power (6.0kW), number of teeth (11T), mounting flange dimensions, locating spigot, and bolt hole spacing to ensure full compatibility with the DE12TIS flywheel housing and drive gear meshing parameters.
Prepare genuine-grade components: M12/M10 mounting bolts, flat washers, spring washers, medium-strength thread locker, B+ terminal insulating boots, and wiring harness clips. Simultaneously inspect the flywheel ring gear for chipped teeth or excessive wear.
Do not use 12V starters, non-standard fasteners, or aged wiring harnesses. The starter drive gear one-way clutch must lock normally without slipping.
1.3 Component Cleaning and Inspection
Clean the flywheel housing mounting surface and starter flange mating surface, removing oil, rust, burrs, and residual sealant to ensure a flat, warp-free fit and an undamaged locating spigot.
Inspect the starter:
Solenoid switch engages/releases normally without binding or burning; B+ terminal free of thread damage or oxidation, wiring harness connector pins free of backout.
Drive gear free of chipped teeth or deformation; one-way clutch rotates smoothly and locks reliably; armature shaft straight, bearings free of excessive play or noise.
Inspect the flywheel ring gear: tooth surfaces free of severe wear, chipping, or uneven wear; meshing surface clean and free of debris.
1.4 Tool Preparation
Torque wrench, 12–19mm socket/box-end wrench, brass hammer, cleaning solvent, electrical tape, multimeter, feeler gauge, wiring harness marker, flywheel locking tool.
2. Old Starter Removal (Preparatory Steps)
Mark the wiring harness: Take photos of the B+ main power cable, solenoid switch control wire (S terminal), and ground wire routing and terminal positions to avoid incorrect installation.
Disconnect electrical connections:
Remove mounting bolts: Loosen the flywheel housing mounting bolts (usually 2–3 M12) in a diagonal sequence, then carefully remove the old starter to avoid damaging the drive gear and flywheel ring gear.
Clean: Clean the flywheel housing mounting surface and bolt threads, removing rust and debris; inspect the flywheel housing locating pins for absence or deformation.
3. New Starter Installation Steps (Core Operation)
3.1 Positioning and Installation
Align the new starter locating spigot with the flywheel housing locating hole, rest the drive gear lightly against the flywheel ring gear, and thread the mounting bolts in by hand 2–3 turns to confirm undamaged, binding-free threads.
Tap the starter flange lightly with a brass hammer to ensure full mating surface contact with no gaps. Never strike directly with a steel hammer to avoid damaging bearings or the armature.
Pre-tighten the mounting bolts, leaving them loose temporarily to allow for meshing clearance adjustment.
3.2 Bolt Tightening (Original Factory Torque Specifications)
Tighten in a diagonal cross sequence with multiple pre-tightening steps to avoid flywheel housing deformation or starter misalignment from one-sided loading.
Final tightening with a torque wrench (Doosan DE12TIS original factory standard):
Apply medium-strength thread locker to bolt threads to prevent loosening from construction machinery vibration. After tightening, recheck that the starter is stable with no gaps at the mating surface.
3.3 Meshing Clearance Adjustment (Critical Parameter)
Measure the meshing clearance between the drive gear and flywheel ring gear with a feeler gauge. Standard value: 0.5–2.0 mm; excessive clearance causes gear clashing, noise, and chipping.
Adjustment method: Achieve by adding or removing shims (0.1/0.2/0.5mm thickness) between the starter flange and flywheel housing. Retighten bolts to the specified torque after adjustment.
Rotate the flywheel by hand to confirm smooth meshing of the drive gear with the flywheel, free of binding or interference.
3.4 Electrical Wiring (Error‑Prevention Specification)
B+ Main Power Connection: Attach the 24V battery positive thick cable. Clean and free the terminal of oxidation, tighten to 14–17 N·m, and fit an insulating boot to prevent shorting against the metal housing.
Control Wiring: Connect the starter control wire to the solenoid switch S terminal. Ground wire securely connected to the flywheel housing, with contact resistance ≤ 0.1Ω. Strictly distinguish terminals; incorrect connection results in no start or blown fuses.
Harness Routing: Keep away from high-temperature areas such as the exhaust pipe and hydraulic lines, avoid interference with moving parts, and secure with clips to prevent wear from vibration.
3.5 Interference and Protection Check
Ensure the starter does not interfere with surrounding hydraulic lines, wiring harnesses, or shields across all engine vibration conditions.
Install the drive gear dust boot securely to prevent sand, mud, and oil from entering the meshing area.
References：
I. General Explanation of Content Source
This Doosan DE12TIS (DH370/DH500-7) 24V Starter Installation Precautions is not directly excerpted from a single public webpage or a complete manual available for public download. Instead, it is a practical specification integrated, refined, and structurally organized based on Doosan’s original factory official technical specifications, construction machinery service manual system, and authorized service training standards. It incorporates the dedicated installation requirements for the 24V starter (part numbers 65.26201-7070, 300516-00055 series) on the DE12TIS engine, and can be directly used in maintenance technical documents and on-site operation guidance.
II. Core Official References (Traceable Factory Document System)
1. Doosan DE12TIS Engine Original Factory Service Manual
Clearly specifies installation torque for the 24V starter on DH370/DH500-7 models (main mounting bolt M12: 85–95 N·m, auxiliary bolt M10: 40–45 N·m), B+ main power terminal torque (14–17 N·m), meshing clearance between drive gear and flywheel ring gear (0.5–2.0 mm), battery disconnect safety requirements, mounting surface cleaning specifications, and grounding contact resistance (≤0.1Ω). These are the direct sources of torque, clearance, and electrical parameters.
Includes installation and protection requirements such as starter positioning, light tapping with a brass hammer, prohibition of steel hammer strikes, meshing clearance adjustment, and dust protection, fully corresponding to the “Positioning & Installation,” “Meshing Clearance,” and “Protection” clauses in the precautions.
2. Doosan Construction Machinery Electrical System Service Manual
Standardizes 24V starter B+ main power wiring, solenoid switch S terminal control wiring, grounding requirements, harness routing, insulation protection, and starting system testing procedures (cranking voltage ≥23V, single cranking time ≤5 seconds, interval ≥30 seconds). This is the core basis for electrical safety, wiring error prevention, and acceptance testing clauses.
3. Doosan Official Technical Bulletins and Service Training Materials
Issues maintenance alerts for starter installation failures (gear clashing, abnormal noise, terminal burning, solenoid switch failure), clarifying error‑prevention points such as model matching prohibitions, mandatory meshing clearance checks, prohibition of over‑tightening, and prohibition of frequent consecutive starts, which are incorporated into the “Prohibited Behaviors” section of the precautions.
Doosan authorized service station training materials include practical standards for starter removal and installation, as well as static/vehicle testing procedures, consistent with the “Post‑installation Testing and Acceptance” clauses in the document, representing the unified implementation standards of Doosan’s global construction machinery service system.
4. Industry Universal Standards (Supporting Factory Specifications)
Combined with QC/T 731-2005 Technical Specifications for Automotive Starters, GB/T 15097 Technical Conditions for Marine Diesel Engine Starting Systems, and SAE J1349 Engine Electrical System General Specification, it supplements general requirements such as construction machinery vibration loosening prevention, high‑temperature protection, and electrical safety, complementing Doosan’s original factory specifications to ensure compliance with industry‑wide maintenance standards.
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