Alternators 11203666 VG1246090005 AAK5735 11.203.666 ID-E162 for HOWO A7

Pre-installation Preparation

• Turn off the vehicle and wait for the engine to cool down completely. Disconnect the negative cable of the battery to avoid short circuits during installation, which could damage electrical components or cause electric shock hazards.

• Inspect the new generator for any external damage and verify that its model is compatible with the Howo vehicle. Meanwhile, clean dust, oil, and debris from the generator's mounting position to ensure the mounting surface is flat and clean. Additionally, prepare supplies such as thread-locking adhesive for subsequent bolt anti-loosening.

Initial Securing of the Generator Body

• Place the 28V generator steadily on the engine's mounting bracket and align it with the bolt holes on the bracket. Initially secure it with corresponding bolts through the mounting holes, but do not fully tighten them. Leave some room for movement to facilitate subsequent adjustment of the pulley position and belt tension. If the mounting surface is slightly uneven, use thin metal shims for fine adjustment to ensure the generator body is stable.

Connecting Electrical Circuits

• Howo generators typically have interfaces for power wires, control wires, etc. Refer to the marks made during disassembly (it is recommended to mark when removing old parts) and reconnect the corresponding wire plugs or terminals to their original positions. Tighten the fixing nuts of the output cables with a wrench to ensure no looseness at the connections. Apply a small amount of thread-locking adhesive to bolted connections to prevent wires from falling off due to vibration during vehicle operation. Pay attention to distinguishing positive and negative poles; never reverse them to avoid damaging internal components of the generator.

Installing and Adjusting the Drive Belt

• Fit the drive belt onto the generator pulley and the corresponding engine pulley in sequence. Use a belt tensioner tool to adjust the belt tension. The tension should be moderate—pressing the belt should produce a deflection of 1-2 centimeters. Excessively loose belts will slip and affect power generation efficiency, while overly tight belts will accelerate wear on the generator bearings and the belt itself. After adjustment, rotate the pulley again to ensure the belt fits properly without deviation.

Tightening and Rechecking

• Use a torque wrench to evenly tighten the generator's fixing bolts diagonally according to the vehicle's specified torque, ensuring the body is firmly secured to the bracket to prevent vibration during operation. Then recheck that the electrical connections are secure and the belt is properly installed. Once confirmed, reconnect the negative battery terminal.

Test Operation

• Start the vehicle and observe whether the charging indicator light on the instrument panel turns off normally. At the same time, use a multimeter to measure the voltage across the battery. A properly functioning 28V generator in Howo vehicles typically maintains a stable voltage between 28-30V. If the indicator light functions normally and the voltage is stable, the installation is qualified. If abnormalities occur, stop the vehicle and check the wire connections, belt tension, or other potential issues.

1. Core Safety Operations

• Disconnect the negative battery terminal throughout the entire process and do not reconnect it until the installation is complete to eliminate the risk of short circuits or electric shock.

• Avoid touching high-temperature engine components, rotating parts such as pulleys with hands during operation. Clear tools before starting the vehicle after installation to prevent entanglement.

• Use matching tools (e.g., torque wrench, special tensioner). Never tighten bolts with brute force to avoid damaging the mounting bracket or generator housing.

2. Installation Accuracy Requirements

• The generator model must be compatible with the Howo vehicle to prevent unusability or operational abnormalities caused by mismatched voltage or mounting hole positions.

• Tighten the fixing bolts evenly and diagonally according to the vehicle's specified torque (usually 25-35N・m, subject to the vehicle manual). Thread-locking adhesive can be applied for anti-loosening.

• Strictly control the belt tension to a "deflection of 1-2 centimeters when pressed". An overly loose belt will slip, while an overly tight one will wear the bearings. After adjustment, manually rotate the pulley to confirm no deviation.

3. Circuit Connection Taboos

• Verify the positive and negative poles and circuit marks before wiring. Never reverse the power wires or control wires, as this will burn out the generator rectifier or vehicle electrical appliances.

• Ensure the wiring terminals are clean and free of oxidation. Avoid pulling the wires when tightening the fixing nuts to prevent wire detachment or poor contact.

• Do not plug or unplug wires while the generator is running. Recheck all connectors for firmness, no looseness, or exposed metal before testing.

4. Operation Inspection and Subsequent Maintenance

• After the first start, first observe if the charging indicator light turns off, then use a multimeter to measure the battery voltage (28-30V is normal). Only drive normally if there are no abnormalities.

• Pay attention to the generator's operating noise in the short term after installation. If there is abnormal noise, check if the belt tension is appropriate or if the bearings are properly installed.

• Regularly clean dust and oil from the generator surface to avoid poor heat dissipation. Meanwhile, inspect the fixing bolts and wire connectors to prevent loosening due to vibration.

5. Special Scenario Reminders

• If bracket deformation or belt aging is found when removing the old generator, replace them simultaneously to avoid affecting the service life of the new generator.

• Those without experience in commercial vehicle electrical maintenance are not recommended to operate independently. Prioritize contacting Howo after-sales service or professional maintenance personnel to avoid secondary damage.

References：

General Installation Guidelines for Automotive Generators

Detailed Installation Specifications for Industrial and Commercial Vehicle Generators

Maintenance Logic Related to Howo Models