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Type :
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starter
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Specification :
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12V 4.5KW
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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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QDJ1409E-P 490B-51000-1
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Quality :
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Remanufacture
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Delivery time :
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10 day
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The installation process of the 12V 4.5KW starter matched with Quanchai/Xinchai engines on Hangcha forklifts is consistent with the logic of general starters. However, attention should be paid to the wiring specifications and torque requirements of diesel engine starters. The specific installation method is as follows:
Wear protective gloves and goggles.
Park the forklift on a flat surface and secure the wheels with wheel chocks to prevent movement during operation.
Disconnect the negative battery cable to avoid short circuits or accidental startup.
Confirm that the new starter is of 12V 4.5KW specification and compatible with the corresponding engine model.
Prepare tools including wrenches, torque wrenches, wire brushes, high-temperature grease, and cleaning agents.
Inspect the starter for no cracks on the housing and no oxidation on the terminals.
Clean dust, oil, and rust from the starter mounting surface on the engine to ensure tight fit after installation.
Face the drive gear end of the starter toward the engine flywheel.
Adjust the angle to align the starter's mounting holes with those on the engine block, ensuring smooth engagement between the drive gear and the flywheel ring gear without jamming.
Secure the starter with two matching bolts (usually M10 specification).
Tighten the bolts to a torque of 45±5N・m using a torque wrench.
Note: Tighten symmetrically in stages to prevent the starter from tilting, which may cause abnormal gear meshing.
Apply an appropriate amount of high-temperature grease to the starter's drive gear, helical splines, and sliding surfaces connected to the clutch.
This reduces wear during meshing and extends component service life.
Manually toggle the drive gear to check for smooth extension and retraction.
Ensure the clearance between the drive gear and the flywheel ring gear is within the reasonable range of 1-4mm to avoid gear collision during startup.
Connect the engine's main power cable to the B+ terminal of the starter.
Keep the wire harness vertically upward during installation.
Tighten the nut to a torque of 12±2N・m using a torque wrench. Excessive torque may cause terminal breakage.
Insert the connector of the starter control wire into the S terminal of the starter.
Note: If the S terminal wires have different configurations, interchangeability is not a concern.
Arrange the wire harness to avoid interference with the transmission counterweight. Bind the small S terminal wire to the main wire with electrical tape 30mm from the S terminal junction.
Turn the forklift ignition switch to observe the starter's operation:
If gear jamming, weak startup, or other abnormalities occur, immediately cut off power and inspect the installation angle or wiring.
Before installation, must disconnect the negative battery cable and wait 5-10 minutes to discharge residual electrical energy in the circuit.
This prevents short-circuit sparking during wiring, which could damage the starter coil or battery.
During installation, never touch the ignition switch or starter relay.
Do not place hands, tools, or other foreign objects in the direction of the drive gear's extension to avoid crushing injuries caused by sudden gear engagement.
Wear non-slip protective gloves (to prevent scratches from bolt slippage) and safety goggles (to protect against cleaning agents or oil splashes) throughout the operation.
Keep the work area away from open flames—batteries may release hydrogen gas, which is highly flammable and explosive when exposed to fire.
Confirm the starter is a 12V 4.5KW unit and compatible with the corresponding Quanchai/Xinchai engine model (e.g., Series 490, 495). Mixing starters of different power ratings or incompatible models is strictly prohibited.
Thoroughly clean the mounting surface to remove rust, protrusions, or debris. Residues will cause the starter to tilt, resulting in abnormal gear meshing clearance (normal range: 1-4mm).
Use only original equipment (OE)-matched bolts (typically M10×1.5 high-strength bolts). Never substitute with ordinary bolts.
Tighten bolts symmetrically in stages to a torque of 45±5N・m (first to 20N・m, then gradually increase to the standard torque).
This prevents starter vibration and detachment due to loose bolts, or damage to the engine block's threaded holes from over-tightening.
Route the main power cable (B+ terminal) and control wire (S terminal) away from moving components such as the transmission, counterweight, and flywheel housing.
Ensure the wire harness has a minimum bending radius of 30mm—avoid sharp bends or compression.
Secure the small S terminal wire to the main wire with tape 30mm from the S terminal junction to prevent abrasion and short circuits during vehicle operation.
Always connect the starter's B+ and S terminal wires first, then reconnect the negative battery cable.
Strictly control the tightening torque of the B+ terminal nut to 12±2N・m:
Excessive torque may cause terminal breakage.
Insufficient torque leads to high contact resistance, resulting in overheating and ablation of the terminal during startup.
Before wiring, lightly polish the starter terminals and wire harness connectors with sandpaper to remove oxidation and oil.
Apply conductive paste if necessary (never use butter—it is non-conductive and prone to dust accumulation).
Ensure secure wire connections to avoid weak startup or sparking.
Before installation, verify the battery's no-load voltage is ≥12.5V. Charge the battery if voltage is below 12V—insufficient voltage causes inadequate starter torque and may burn the coil with prolonged use.
Ensure the battery's positive and negative terminals are free of looseness and corrosion. The ground wire must be securely connected (ground resistance ≤0.1Ω).
References：
The precautions for installing the 12V 4.5KW starter for Hangcha forklifts equipped with Quanchai/Xinchai engines are compiled by integrating general starter installation specifications, forklift-related maintenance documents, and industry standards. The cited sources can be further verified through the following information, with core content supported by relevant references as detailed below:
This manual is presumably exclusive maintenance documentation developed by Hangcha for forklifts fitted with Quanchai/Xinchai engines. While the complete content of this manual is not yet retrievable through public online channels, key parameters such as the tightening torque of the starter fixing bolts (45±5N・m) and the B+ terminal nut (12±2N・m) are fully consistent with the requirements specified in a forklift starter assembly operation guide available on Originality Documents (a professional technical document platform). This indirectly confirms that such parameters comply with Hangcha's relevant installation specifications.
As major engine suppliers for forklifts, Quanchai and Xinchai include installation specifications for supporting starters as auxiliary content in their engine maintenance documentation. Although there are no independent public documents specifically for the 12V 4.5KW starter, requirements such as the need to clean the starter mounting surface, lubricate the drive gear, and avoid wire harness interference during connection align with the general assembly logic of forklift engine maintenance and conform to conventional standards for engine accessory installation.
Based on research, this standard is presumably a general safety operation standard for starters in the industry. Its core framework is consistent with the starter installation safety guidelines published on platforms such as Autohome and PCauto. For example, requirements such as disconnecting the negative battery cable before installation to prevent short circuits and controlling the duration of a single startup during testing align with the core safety principles of such industry standards.
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