car alternator for KOBELCO for HINO 500 J08C E13C 24V 60A KA-11-2101 27040-2191 ALT9817 270402380A 02011720510

Pre - installation Preparation

1. Park the vehicle on a flat surface. After turning off the engine, pull the handbrake tightly and disconnect the negative cable of the storage battery to prevent short circuits during installation from damaging electrical components related to the 28V system.

2. Prepare special tools such as socket wrenches, special tools for belt tensioners, torque wrenches, and cleaning rags. Verify that the model of the new 28V generator matches the corresponding Hino vehicle model. Check that the generator has no external damage, its bearings rotate smoothly without jamming, and the connecting terminals are free of rust and oxidation.

3. If the old generator was removed before, ensure that the connection positions of all cables have been recorded. At the same time, use a cleaning rag to wipe off dust and oil stains on the generator mounting bracket to avoid impurities affecting the fitting degree during installation.

Initial Fixation of the Generator Body

1. Place the new generator steadily on the engine's mounting bracket, and accurately align it with the fixing bolt holes to prevent inclination during installation.

2. Install the fixing bolts with a socket wrench and only tighten them initially without fully screwing them in. For some Hino models equipped with through - mounting bolts, ensure that the sleeve slides to be flush with the surface of the bracket before inserting and fixing the bolts. This reserves space for adjusting the tension of the drive belt later.

Connection of Electrical Circuits

1. Locate the output cable interfaces and wire connectors on the generator, and connect the cables in accordance with the marks made during removal. The power cables, field windings and other wires of the 28V generator must be connected to their corresponding dedicated interfaces. Incorrect connection is strictly prohibited to avoid power generation failures.

2. Tighten the fixing bolts of the terminals with a wrench to ensure the cables are connected firmly without loosening. For models equipped with terminal anti - short - circuit covers, install them promptly after completing the cable connection to prevent short circuits or electric leakage.

Installation and Adjustment of the Drive Belt

1. Use a belt tensioner tool to loosen the tension pulley, then accurately fit the drive belt onto the generator pulley and the corresponding engine pulley. Ensure the belt fits perfectly into the pulley grooves without deviation or misalignment.

2. Slowly release the tensioner to adjust the belt tension. You can press the middle part of the belt; normally, a vertical deflection of 1 - 2 centimeters when pressed indicates proper tension. After adjustment, manually rotate the pulley to confirm that the belt runs without jamming. This avoids problems such as insufficient power generation efficiency caused by loose belts slipping, or accelerated wear of bearings and the belt due to over - tightness.

Final Fastening and Post - installation Inspection

1. After the belt tension is properly adjusted, fully tighten the generator's fixing bolts with a torque wrench. Control the tightening torque with reference to relevant Hino maintenance specifications to prevent resonance during operation.

2. Re - check the installation of all cables and the drive belt. Once confirmed that there is no loosening, reconnect the negative cable of the storage battery and make sure the connector is fastened securely.

Post - installation Testing and Verification

1. Start the vehicle and observe whether the charging indicator light on the instrument panel goes out normally. If the indicator light stays on continuously, it may indicate a faulty cable connection or improper belt installation.

2. Gently press the accelerator to increase the engine speed, and listen for abnormal noises such as bearing rumbles or belt slipping during the generator's operation. Use a multimeter to test the output voltage; the normal output voltage of the 28V generator should comply with the vehicle model's standards. If the voltage is too low or too high, it is necessary to check for faults in the cables or the voltage regulator.

3. Avoid high - load power consumption of the vehicle (such as turning on the air conditioner, vehicle lights, and audio system simultaneously) in the short term after installation, allowing the generator and the belt to run - in fully. If abnormalities such as flickering of the charging indicator light occur, stop the engine immediately for inspection.

1. Bottom Lines for Safe Operation

• Disconnect the negative battery cable first and do not reconnect it until installation is complete. The 28V system voltage is higher than that of ordinary passenger cars, which eliminates the risk of short circuits and electric shocks. Avoid tools touching both positive and negative terminals of the generator simultaneously during operation.

• Perform construction only after the engine compartment has cooled down. Commercial vehicle engine compartments are compact with many high-temperature components to prevent scalding. Wear insulating gloves and safety goggles to avoid metal tools slipping and damaging electrical components or causing short circuits.

• Use special belt tensioner tools for commercial vehicles when removing or installing the belt. Do not pry the tension pulley or belt pulley with brute force, as this may damage the tensioner spring, bearings, or pulley grooves and affect transmission stability.

2. Verification of Component Compatibility and Condition

• The new generator must be fully compatible with the engine model of the corresponding Hino vehicle (e.g., Series 700, Series 500, etc.). Focus on verifying power, mounting hole positions, pulley specifications, and terminal types. Do not confuse the 28V system voltage level to avoid abnormal power generation or damage to electrical equipment.

• Inspect the new generator before installation: bearings should rotate smoothly without jamming or abnormal noise, the housing should be free of damage and deformation, terminals should be free of oxidation and rust, and internal components such as the regulator and rectifier bridge should be intact. Simultaneously check that old wires have no cracks, aging, or adhesion, and that plug interfaces are not loose. Repair or replace faulty wires first.

• Confirm the drive belt has no cracks, aging, or missing teeth. Commercial vehicle generator belts bear greater loads; if used for more than 1.5 years or severely worn (e.g., shallow pulley grooves), it is recommended to replace them simultaneously. The belt model must match the generator pulley; do not randomly replace specifications.

• References：
• The "installation method" and corresponding "precautions" for the 28V generator of Hino vehicles you previously inquired about are not derived from a specific official authoritative document or a single exclusive material of Hino. Instead, they are compiled by integrating universal installation specifications for commercial vehicle generators, Hino model-related accessory information, and general practical guidelines in the automotive maintenance field. The specific reference directions are as follows:

• 1. Hino-related Accessory and Compatibility Information

• Accessory platforms such as Shunqi Wang (Shunqi Network) have marked the parameters of relevant accessories such as the 28V Sato generator adapted for Hino trucks, clarifying core compatibility attributes like the generator’s rated voltage. This serves as an important reference for verifying component compatibility during installation, avoiding installation failures caused by mismatched models.

• 2. Universal Generator Installation and Maintenance Specifications

• Materials such as the generator technical service guide compiled on Docin.com and the automotive generator installation specifications from the Breadboard Community specify general requirements including generator installation spacing, circuit disconnection procedures, and bolt tightening torque. For example, the spacing between the installation position and other components should not be less than 10mm, and the battery connection cable must be disconnected before disassembly/installation. These requirements are equally applicable to the installation of Hino’s 28V generator.

• 3. Universal Practical Procedures for Automotive Generator Installation

• The installation steps for automotive generators published on platforms such as PCauto and Autohome cover core processes including removing old parts, cleaning the installation site, preliminary fixing of the generator body, wiring, adjusting belt tension, and test verification. As an automotive brand (primarily focusing on commercial vehicles), Hino’s 28V generator installation process is consistent with these universal procedures, requiring only adaptations to its own engine structural details. This content provides the core framework for organizing the installation steps.