DoorKing 6524 DC Swing Gate Operator Parts
DoorKing 6524 DC Swing Gate Operator Replacement Parts
Genuine DoorKing replacement parts for the 6524 DC swing gate operator (model 6524-380, drawing 6524-380 Rev D). Part numbers on the diagrams are called out by number rather than by reference key, so the tables below list them in numeric order. Click any part number to go straight to that product page.
The 6524 is the battery-backed DC version of the DoorKing 6500. Everything mechanical is shared — the 6500-152 base, 6500-400 hub, 6500-118 shaft support, 6500-430 arm, 2600-719 gearbox, 2600-597 pulley, 6500-047 belt and all four covers are the same parts.
What is unique to the 6524: a 24 VDC motor (2601-197) fed by a 300VA transformer (4001-089), bridge rectifier (1860-073) and 4700 uF capacitor (3500-023), two 12V 7.2 Ah batteries (1801-003) on a DC battery tray (6500-313), the 4100-018 control board and the 6524-005 enclosure cover. The 6500 uses an AC motor and the 4405 board instead.
Circuit Board — the most replaced part on the 6524
4100-018 — PCB Gate Operator
The 6524 and the 9024 use the 4100 board family. Replace it when the operator is dead with power confirmed at the terminals, when it powers up but ignores every input (radio, keypad, loop, push button), when only one direction works, or after a lightning or surge event.
The 4100 family is different from every other DoorKing board. There is no single part number with a date dropdown — there are four separate boards, and you order the one that matches your operator. Match on both the build date and the motor voltage:
| Part Number | Fits |
|---|---|
| 4100-018 | Current board. 6524 and 9024 operators built January 2016 or later, with the UL325 monitored device input. |
| 4100-012 | 6524 and 9024 operators built prior to January 2016. |
| 4100-019 | Operators with the 24 VDC motor. |
| 4100-013 | Pre-UL operators with the 30 VDC motor. |
If you are unsure which you need, read the number printed on the board currently fitted — it will end in -012, -013, -018 or -019. Only the 4100-018 can be ordered online at present; for the other three call (866) 965-5599 and we will get one on the way.
Replace the 4001-109 varistor assembly at the same time as any surge-killed board — a surge big enough to take the board out almost always takes the varistor with it, and a spent varistor leaves the new board unprotected. Check the 4601-053 fuse assembly and the 4001-020 20-pin terminal while the enclosure is open.
Front View — Covers, Hub, Switch Box & Sensors
Turret, hub and shaft support
Covers, switch box and mounting
| Part Number | Description | Qty |
|---|---|---|
| 1200-023 | Snap-in outlet (Qualtek) | 2 |
| 1400-022 | Push button switch, snap-in red | 1 |
| 1506-071 | Tone generator alarm, loud | 1 |
| 1601-261 | Magnetic sensor switch, recessed orange | 1 |
| 1601-263 | Magnetic sensor switch, recessed yellow | 1 |
| 1702-505 | Cam, 9/16 in. | 1 |
| 2599-006 | Label, ground | 1 |
| 2600-401 | Slide switch, voltage select (115 / 230 V) | 1 |
| 2600-402 | Rocker switch, ON/OFF snap-in SP | 1 |
| 2600-408 | Rocker switch, ON/OFF snap-in DP | 1 |
| 2600-413 | Terminal block, 3 position | 1 |
| 2600-528 | Switches and alarm box | 1 |
| 2600-731 | Gasket, switch cover | 1 |
| 2601-348 | Spacer, cover left | 2 |
| 2615-053 | Hex bolt, 3/8-16 x 1-1/4 in. | 2 |
| 2615-055 | Hex head bolt, 3/8-16 x 1-1/2 in. | 4 |
| 2615-430 | Flat head hex bolt, 3/8-16 x 3/4 in. SS | 4 |
| 2616-002 | Phillips head screw, 6-32 x 1/2 in. | 2 |
| 2616-051 | Phillips head screw, 10-32 x 3/8 in. | 2 |
| 2616-062 | Phillips head screw, 10-32 x 3 in. zinc | 2 |
| 2620-019 | Washer, 3/8 in. ID SAE | 4 |
| 2620-047 | Lock washer, 3/8-16 | 6 |
| 2620-405 | Hex nut, 3/8-16 | 4 |
| 2620-409 | Hex flange lock nut, 1/4-20 | 2 |
| 2620-411 | Hex flange lock nut, 5/16-18 | 13 |
| 2902-006 | Nylon lock nut, 10-32 | 2 |
| 4001-055 | Cabinet lock, 180 deg | 1 |
| 6500-106 | Switch box bracket | 1 |
| 6500-118 | Shaft support assembly | 1 |
| 6500-200 | Hub clutch release tool | 1 |
| 6500-307 | Cover lock panel | 1 |
| 6500-400 | Hub assembly | 1 |
| 6500-440 | Turret cover assembly | 1 |
| 6500-454 | Front cover, slip and lock | 1 |
| 6500-464 | Back cover with labels | 1 |
| 6600-035 | Limit switch, single sensor | 2 |
Back View — DC Motor, Transformer, Batteries & Drive
| Part Number | Description | Qty |
|---|---|---|
| 1801-003 | Battery, 12V 7.2 Ah — replace as a pair | 2 |
| 1860-073 | Bridge rectifier, 35 amp | 1 |
| 2600-238 | Capacitor mounting clamp, 35 mm | 1 |
| 2600-597 | Pulley, 13 in. cast iron AK130 x 7/8 | 1 |
| 2600-719 | Gearbox, swing gate splined | 1 |
| 2600-810 | Bushing, 7/8 in. poke thru flaps | 9 |
| 2601-197 | Motor, DC 4 in. dia. — call for current availability | 1 |
| 2615-082 | Hex head bolt, 1/2-13 x 2 in. | 4 |
| 2615-153 | Hex head bolt, 5/16-18 x 3/4 in. | 3 |
| 2615-655 | Carriage bolt, SS 5/16-18 x 2-1/2 in. | 1 |
| 2620-028 | Washer, 5/16 in. USS | 5 |
| 2620-050 | Lock washer, 1/2 in. | 4 |
| 2620-076 | Washer, 1.125 ID x 1.63 OD x .125 T | 2 |
| 2620-420 | Hex nut, 1/2-13 | 4 |
| 2620-494 | Jam nut, 3/4-16 | 2 |
| 2630-007 | Snap ring, 1.125 in. ID | 1 |
| 2902-003 | Nylon lock nut, 6-32 | 3 |
| 3500-023 | Capacitor, 4700 uF 63V screw terminal | 1 |
| 4001-089 | Transformer, 300VA 115/230 to 24V | 1 |
| 6500-025 | Bolt, centre tapped | 2 |
| 6500-047 | Belt, 47 in. for 13 in. pulley (4L470) | 1 |
| 6500-121 | Capacitor plate | 1 |
| 6500-152 | Base stand, swinger | 1 |
| 6500-313 | Battery tray, DC | 1 |
PCB Enclosure — Control Board & Terminals
| Part Number | Description | Qty |
|---|---|---|
| 1400-021 | Momentary rectangular button switch | 1 |
| 2599-014 | Decal, copper wire only | 1 |
| 2599-096 | Label, push to operate | 1 |
| 2600-410 | Marker strip, silkscreened both sides | 1 |
| 2600-414 | Terminal block, 2 position | 1 |
| 2600-439 | Brass ground washer | 1 |
| 2600-805 | Bushing, 1-3/32 in. poke thru flaps | 2 |
| 2601-355 | Spacer, nylon 5/8 in. L x 3/8 in. ID | 3 |
| 2616-001 | Phillips head screw, 6-32 x 3/8 in. | 8 |
| 2616-003 | Phillips head screw, 6-32 x 3/4 in. SS | 2 |
| 2616-019 | Phillips head screw, 8-32 x 3/4 in. | 4 |
| 2902-007 | Keps lock nut, 5/16-18 | 3 |
| 2902-010 | Nylon lock nut, 8-32 | 1 |
| 3129-002 | Terminal block cover, 2 position | 1 |
| 4001-020 | Terminal, 20 pin | 1 |
| 4001-109 | MOV assembly, 275 VAC varistor | 1 |
| 4100-018 | PCB, gate operator (control board) — see the control board box above and match your build date and motor voltage | 1 |
| 6524-005 | Cover, plastic screened | 1 |
| 9350-100 | Enclosure, model 9000 | 1 |
Not Shown on the Diagrams
| Part Number | Description | Qty |
|---|---|---|
| 1860-032 | Nylon retaining washer, #6 | 2 |
| 2344-037 | Wire harness, 2 position | 1 |
| 2599-038 | Label, radio | 1 |
| 2599-100 | Warning sign | 2 |
| 2599-220 | Label, caution remove rod | 1 |
| 2600-619 | Wire clip, 5/8 in. | 3 |
| 2601-094 | Wire tie, 16 in. black | 4 |
| 2601-297 | Terminal, 187 quick disconnect insulated | 2 |
| 2616-000 | Phillips head screw, 6-32 x 1/4 in. | 2 |
| 2616-007 | Phillips head screw, 6-32 x 5/8 in. | 2 |
| 2616-018 | Phillips head screw, 8-32 x 1/2 in. | 6 |
| 2616-097 | Set screw, 5/16-18 x 3/8 in. | 2 |
| 2900-905 | Standoff, aluminium 7/16 in. 6-32 | 1 |
| 2902-004 | Nylon lock nut, 8-32 | 4 |
| 4001-021 | Polarizing key | 1 |
| 4601-053 | Fuse assembly | 1 |
| 6500-430 | Main arm assembly | 1 |
| 6524-065 | Installation manual | 1 |
| 7082-186 | Wire set, 6524 swing | 1 |
| 9024-136 | Wire, RS485 cable 50 ft | 1 |
| 9024-197 | Resistor assembly, bleeder | 1 |
| 9402-053 | Flex split tubing, 1/4 in. OD | 1 |
| 9402-055 | Flex split tubing, 1/2 in. OD | 1 |
Superseded Part Numbers
| Old Part Number | Current Part Number | Notes |
|---|---|---|
| 6500-453 / 6500-463 | 6500-454 / 6500-464 | Rev B replaced the front and back covers |
| 4001-035 | 4001-055 | Rev C replaced the cabinet lock |
| 6500-123 + 6500-148 | 6500-118 | Rev D replaced both with the single 6500-118 shaft support assembly |
| 6600-030 / 6600-032 | 6600-035 | Rev D replaced both limit switches with the 6600-035 single sensor, two required |
| 6500-284 | 6500-307 | Rev B replaced the cover lock panel bracket |
Common 6524 Problems and the Parts That Fix Them
| Symptom | Usual Cause | Parts |
|---|---|---|
| Gate will not run at all, no lights on the board | Failed fuse, transformer or rectifier | 4601-053 fuse first, then 4001-089 transformer and 1860-073 rectifier |
| Gate runs slowly or dies after a few cycles | Tired batteries | 1801-003 batteries (2, replace as a pair), 6500-313 battery tray |
| Motor hums or runs rough | Failed DC motor or filter capacitor | 2601-197 DC motor, 3500-023 capacitor, 2600-238 clamp |
| Squealing on start, or motor runs and the gate barely moves | Glazed or stretched drive belt | 6500-047 belt, 2600-597 pulley |
| Grinding or oil leaking from the gearbox | Failed gearbox | 2600-719 gearbox, 2630-007 snap ring |
| Gate will not stop at the open or closed position | Limit sensor fault | 6600-035 limit switches (2), 1601-261 / 1601-263 sensors |
| Operator powers up but ignores every input — radio, keypad, loop and push button all dead | Failed control board logic | 4100-018 board (match your build date and motor voltage), 4001-020 20-pin terminal |
| Dead operator after a storm, no response to any input | Surge-damaged control board | 4100-018 board, 4001-109 varistor, 4001-020 terminal |
| Cover cracked or faded after years outdoors | UV damage | 6500-454 front, 6500-464 back, 6500-440 turret |
Related DoorKing Pages
The 6524 shares its mechanics with the DoorKing 6500, and its DC control kit — board, transformer, rectifier, capacitor, batteries and varistor — with the DoorKing 9024. Other DoorKing swing gate operator parts: 6050 · 6100 · 6300 · 6006 actuator · all DoorKing gate operator parts. Need a complete unit rather than parts? See DoorKing swing gate operators.