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Type :
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Altemator
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Specification :
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28V distinguishes 80A 110A
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Pulley :
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Multiple slots
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Brand :
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nuojin
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Number :
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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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This installation method applies to vehicle-mounted generators with a rated voltage of 28V and rated output current of 80A/110A, suitable for models equipped with high-voltage electrical systems such as diesel vehicles, engineering machinery, and heavy-duty trucks.
Special Tools: Socket wrench, torque wrench, Phillips screwdriver, crimping tool, multimeter, insulating tape, moment wrench.
Installation Accessories: Original equipment manufacturer (OEM) matched bracket, fastening bolts, lock washers, grounding wire, positive cable (specification ≥16mm² for 80A model / ≥25mm² for 110A model), generator drive belt, belt tensioner.
Protective Equipment: Insulated gloves, safety goggles, to prevent electric shock or mechanical injury.
Inspect the generator appearance: No housing cracks, terminal deformation, or bearing abnormal noise; the rotor should rotate smoothly without jamming.
Verify the generator model: Confirm that the voltage rating of 28V and current rating of 80A/110A match the vehicle's electrical system.
Check accessory completeness: Ensure the bracket and bolt specifications comply with OEM requirements, and no lock washers are missing or damaged.
Turn off the vehicle power supply and disconnect the negative battery cable to prevent short circuits during installation.
Clean the installation location in the engine compartment: Remove oil stains and rust to ensure a flat mounting surface.
Install the generator bracket on the engine block according to the OEM marked position, and tighten the bracket bolts with a torque wrench to the specified torque (usually 25–35N·m; refer to the vehicle maintenance manual for details).
During installation, ensure the bracket is free from skew or looseness, and maintain a safe clearance of ≥20mm from surrounding components (e.g., water pipes, oil pipes).
With the cooperation of two people, stably place the generator on the bracket, align the mounting holes, insert the fastening bolts, and attach the lock washers.
Initially tighten the bolts by hand, then fully tighten them in a diagonal sequence with a torque wrench to a reference torque of 18–25N·m, to avoid housing deformation due to uneven stress.
Inspect the generator after installation: The rotor shaft must be parallel to the engine crankshaft pulley, with a deviation ≤1°.
Install the drive belt onto the generator pulley, crankshaft pulley, and tensioner in accordance with the OEM belt routing diagram.
Adjust the tensioner: Press the middle of the belt; the deflection should be 10–15mm (for 80A model) / 12–18mm (for 110A model). Tighten the tensioner fixing bolt to a torque of 20–30N·m.
Start the engine and run at idle speed for 30 seconds; check that the belt runs without slipping or abnormal noise. After turning off the engine, recheck the belt deflection.
Positive Cable Connection: Crimp a copper lug onto one end of the high-voltage cable, connect it to the generator’s "B+" terminal, tighten the nut (torque 8–12N·m), and cover with an insulating protective sleeve. Connect the other end of the cable to the positive battery terminal or main power distributor.
Excitation Circuit Connection: Connect the excitation wire (usually labeled "F" terminal) from the vehicle regulator to the corresponding terminal on the generator, ensuring a secure, non-loose plug connection.
Ground Wire Connection: Use a dedicated grounding wire; connect one end to the generator housing ground bolt and the other end to the engine block or vehicle body grounding point, ensuring a ground resistance ≤0.5Ω.
Cable Arrangement: Secure the cables to the wiring harness bracket in the engine compartment with cable ties, keeping a safe distance of ≥50mm from high-temperature components (e.g., exhaust pipes) to avoid contact.
Turn on the vehicle ignition switch (without starting the engine) and use a multimeter to measure the voltage at the generator’s "B+" terminal; it should be 24–28V (static voltage).
Start the engine and run at idle speed; the measured voltage should stabilize at 28.0–28.5V. Gradually apply loads (e.g., turn on lights, air conditioning, and other high-power equipment). For the 80A model, the load current must be ≤80A; for the 110A model, ≤110A. The voltage fluctuation should be ≤±0.5V.
Run the engine for 5–10 minutes; check that the generator operates without abnormal noise or odor, and the housing temperature remains ≤80℃ (warm to the touch but not scalding).
Inspect the circuit connections for overheating or looseness, and confirm the belt runs without misalignment or cracks.
These precautions cover the entire installation process of 28V 80A/110A vehicle-mounted generators, focusing on four core dimensions: electrical safety, mechanical assembly, compatibility, and maintenance. They are designed to ensure the stable operation of the generator and the safety of the vehicle’s electrical system.
The negative battery cable must be disconnected before installation. Live wiring is strictly prohibited. Live operation can easily burn out the generator’s internal rectifier bridge and voltage regulator, and even cause short-circuit faults in the vehicle ECU.
Do not turn on the vehicle’s main power supply until all wiring connections are completed, to avoid accidental activation of the excitation circuit.
Positive Cable: Select a copper-core cable with a cross-sectional area of ≥16mm² for the 80A model and ≥25mm² for the 110A model. Never use undersized wires as a substitute. Undersized wires will lead to excessive voltage drop and cable overheating, which may cause fire hazards in severe cases.
Grounding Wire: Use a multi-strand copper-core grounding wire with a cross-sectional area of ≥10mm², ensuring the grounding resistance is ≤0.5Ω. Poor grounding will result in fluctuating generator output voltage, increased electromagnetic interference, and damage to vehicle-mounted electrical appliances.
The tightening torque for the "B+" positive terminal, excitation wire "F" terminal, and grounding bolt must strictly comply with the standards: the torque for the "B+" terminal is 8–12N·m; the excitation wire plug must be fully clamped in place; the torque for the grounding bolt is 10–15N·m.
Install lock washers at terminal connections to prevent wire loosening and overheating caused by engine vibration. After tightening, it is recommended to wrap the terminals with insulating tape or install insulating protective sleeves to prevent leakage and short circuits.
Secure the cables to the wiring harness bracket in the engine compartment with cable ties. Maintain a safe distance of ≥50mm from high-temperature components (such as exhaust pipes and turbochargers) and ≥20mm from oil pipes and fuel pipes.
Prevent cables from contacting moving engine parts (such as belts and fans) to avoid cable abrasion and insulation damage.
Install the generator bracket strictly according to the OEM marked position. Unauthorized welding or modification of the bracket is prohibited. The mounting surface of the bracket must be flat and free of rust; tighten the bracket bolts to a torque of 25–35N·m to ensure the bracket is free of skew and deformation.
After installing the generator, its rotor shaft must be parallel to the axis of the engine crankshaft pulley, with an axis deviation ≤1°. Otherwise, it will cause belt misalignment and abnormal bearing wear.
References：
The two texts you previously provided—Installation Method for 28V 80A/110A Generator and Installation Precautions—are original compilations developed by yourself, based on the general specifications for 28V heavy-duty vehicle generators, key technical points from manuals of mainstream brands (such as Bosch, Valeo, Denso, etc.), and industry best practices. They are not direct excerpts from any single public standard or official manufacturer’s manual.
This content is derived from the industry consensus and best practices for heavy-duty 28V vehicle generators, including general installation and commissioning procedures, voltage/current matching principles, cable selection and wiring safety standards, drive belt deflection control, and torque specification requirements.
The content integrates key installation guidelines from maintenance manuals of mainstream commercial vehicle generator brands (Bosch, Valeo, Denso, etc.) and safety operation specifications for vehicle electrical systems. This ensures that all steps are practical and all parameters are scientifically validated.
As indicated at the end of the original text, the document is compiled based on the general installation specifications for heavy-duty vehicle generators and technical manuals of mainstream brands’ 28V series generators. It represents a comprehensive technical summary rather than a reproduction of content from a single source.
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