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Type :
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ENGINE STARTER
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Specification :
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12V 0.8KW
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Number of feet :
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8T
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Brand :
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NUOJIN
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Number :
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23300-00H10
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Quality :
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Remanufacture
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Delivery time :
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30DAYS
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The core steps are: first power off and clean, then precise positioning, fasten bolts and circuits according to standard torque, and finally power on for testing. Emphasis is placed on safety, torque control and gap adjustment. The following are general installation methods and forklift-specific key points:
Turn off the key switch and disconnect the negative cable of the battery (to prevent short circuit and accidental start-up); wear protective gloves.
Prepare socket wrench, torque wrench, cleaning agent, new bolts/washers (prefer original factory parts).
Confirm that the new starter is 12V 0.8KW, matching the forklift engine model and the number of teeth of the flywheel ring gear; check for no appearance damage and normal function of the electromagnetic switch.
Inspect the flywheel ring gear for broken teeth or wear, replace if necessary.
Mark the positions of wiring harness terminals (B+, S terminals), first remove the large wire nut of the B+ terminal, then pull out the small wire plug of the S terminal, remove the fixing bolts and take out the old starter.
Thoroughly clean oil stains and rust on the mounting surfaces of the engine and starter to ensure flat fitting.
Align the new starter with the mounting holes, insert the fixing bolts and manually pre-tighten 2-3 turns.
Fasten according to vehicle model specifications with a torque wrench (common M10 bolts: 45±5N·m, subject to maintenance manual), tighten symmetrically and evenly to avoid housing deformation.
First connect the B+ terminal (thick power wire) with the nut torque of about 12±2N·m, and install an insulating protective cover.
Then connect the S terminal (electromagnetic switch control wire) plug to ensure it is clamped in place without looseness.
Check the routing of the wiring harness, keep it away from high-temperature/moving parts such as the flywheel and exhaust pipe, and fix it with cable ties.
Armature shaft axial gap: 0.15-0.5mm, adjustable by adding or reducing washers.
Drive gear and thrust washer gap: 1.5-2.5mm when the contact disc just touches, 0.5-1.5mm when the plunger is fully advanced; adjust with the limit screw and lock it.
Single start-up does not exceed 5 seconds, with intervals of more than 10 seconds to prevent coil overheating; listen to the gear meshing sound—normal sound is clear meshing + stable operation, without tooth hitting or jamming sound.
After start-up, observe whether the starter runs smoothly without abnormal vibration; touch the B+ terminal and wiring harness connector, temperature rise ≤40℃ is normal—if overheated, re-tighten or inspect the wiring harness.
Turn off the forklift key switch and disconnect the negative battery cable before installation (to avoid short circuit that burns electronic control components, wiring harnesses, or causes accidental starter activation); reconnect the negative cable only after installation is complete. It is strictly forbidden to plug or unplug wiring harness terminals while the power is on.
The meshing area between the starter drive gear and flywheel ring gear is unprotected; keep hands away from the flywheel housing opening during installation. Clear tools and debris around the area before testing the start-up to prevent entanglement in moving parts. Wear protective gloves to avoid slipping due to oil contamination or scratches from metal components.
Keep the operation area away from forklift fuel lines and hydraulic oil leak points. Do not strike the starter housing or bolts with metal tools (to prevent sparks that may ignite fuel vapor). If operating in an enclosed warehouse, maintain ventilation during start-up testing to avoid exhaust gas accumulation.
The starter mounting surface must be thoroughly cleaned, free of oil, rust, deformation, or residual sealant. If the original factory is equipped with positioning pins/gaskets, reinstall them in their original positions to ensure the housing fits tightly with the engine block/transmission. Failure to do so may cause uneven bolt stress, housing cracking, or abnormal noise.
Tighten the fixing bolts symmetrically and in stages (pre-tighten all bolts first, then tighten to the specified torque in a diagonal sequence). For common M10 bolts, the torque is 45±5N·m (subject to the forklift’s original factory manual).Do not use an extended wrench for forced tightening; a torque wrench must be used for precise operation. Loose bolts may cause vibration and detachment, while over-tightening can crack the housing or strip threads.
Connection Sequence: First connect the thick power wire to the B+ terminal (torque: 12±2N·m) and install an insulating protective cover. Then connect the electromagnetic switch control wire plug to the S terminal, ensuring it is fully clamped and free of looseness. Reversing the connection sequence may burn out the electromagnetic switch.
Wiring Harness Routing: Route the harness away from high-temperature/moving/high-pressure components such as the flywheel, exhaust pipe, and hydraulic oil pipes. Secure it with high-temperature-resistant cable ties to prevent wear-induced short circuits or damage from extrusion.
The gap must be controlled within 0.15-0.5mm. Excessive gap may cause gear meshing impact, while insufficient gap can lead to jamming. Adjust by adding or removing washers on the starter mounting surface or armature shaft end. After adjustment, manually rotate the armature shaft to ensure there is no resistance.
When the electromagnetic switch contact disc just makes contact, the gap between the gear and thrust washer should be 1.5-2.5mm.
When the plunger is fully advanced, the gap must be reduced to 0.5-1.5mm.
Adjust by rotating the electromagnetic switch limit screw, then lock the nut to prevent loosening and subsequent meshing issues.
References：
The core precautions for installing the 12V 0.8KW starter for Nissan and Komatsu forklifts mentioned are integrated from the following four categories of authoritative and practical sources to ensure professional and actionable content:
Provide vehicle-specific installation specifications, including precise torque parameters such as fixing bolts (45±5N·m) and B+ terminal nuts (12±2N·m), as well as vehicle-adaptive requirements for starter positioning benchmarks, wiring harness routing, and gap adjustment (e.g., armature shaft axial gap of 0.15-0.5mm).
Clearly define electromagnetic switch wiring specifications and flywheel ring gear matching standards, serving as the core basis for installation accuracy and compatibility.
Product specifications from original supporting manufacturers such as Denso and Bosch specify the applicable forklift models for 12V 0.8KW starters, terminal connection torque, and requirements for cleaning and sealing the mounting surface, which cross-verify with the content of original factory manuals.
Such as Automotive Electrical Appliance Maintenance Specifications and Forklift Maintenance Safety Operation Procedures, which stipulate safety guidelines including disconnecting the negative battery terminal before installation, prohibiting striking the starter housing, and limiting single start-up tests to ≤5 seconds with intervals ≥10 seconds—these are the bottom lines of universal industry operations.
Specialized forklift maintenance textbooks (e.g., Forklift Structure, Principle and Maintenance) clarify practical key points such as starter assembly gaps (drive gear and thrust washer gaps of 1.5-2.5mm/0.5-1.5mm), lubrication points, and brush installation, providing theoretical support for installation accuracy.
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