|
Type :
|
Alternator
|
|
Specification :
|
|
|
Pulley :
|
8PK
|
|
Brand :
|
nuojin
|
|
Number :
|
AVI147E3021
|
|
Quality :
|
renovate
|
|
Delivery time :
|
30day
|
Prepare tools such as wrenches, sockets, torque wrenches, and spirit levels. Meanwhile, prepare a matching 8PK specification belt, generator mounting bolts, and lock washers. If the generator terminal posts are oxidized, prepare grinding tools and conductive paste in advance.
For vehicle generators, first disconnect the negative terminal of the vehicle battery to avoid short circuits; some models require removing obstructive components such as oil pipes and power steering fluid reservoirs for easier operation. Inspect the new generator for no external damage, ensure the pulley rotates smoothly without jamming, and check that the terminal posts are free of rust. Additionally, verify that the generator mounting feet match the engine bracket (e.g., corresponding mounting positions for triangular feet, four feet, etc.).
Lift the generator to the generator mounting bracket of the engine, align it with the mounting holes on the bracket, and ensure the generator pulley and the engine crankshaft pulley are in the same plane to prevent uneven belt stress during subsequent operation.
Insert the mounting bolts with lock washers, hand-tighten them initially, then use a torque wrench to uniformly tighten them diagonally according to the manufacturer's specified torque to avoid generator body tilting. After installation, gently shake the generator to confirm there is no looseness.
Locate the belt tensioner on the engine, use a special tool or wrench to pry the tensioner to a relaxed state, creating space for installing the 8PK belt.
Follow the engine belt routing diagram to sequentially fit the 8PK belt into the corresponding pulley grooves (e.g., generator pulley, crankshaft pulley). Ensure the belt is fully seated in the grooves without slipping or misalignment. Two-person collaboration is recommended for this step to facilitate alignment with the grooves.
Slowly release the tool used to pry the tensioner, allowing the tensioner to automatically press the belt. Press the middle section of the belt—normal deflection should be 1-2 centimeters. Excessive slack may cause slipping, while excessive tightness will accelerate bearing wear.
Generators typically have a positive terminal post (marked "B+" in most cases), an excitation terminal post (marked "F" or "D+"), etc.
Connect the corresponding power cable from the engine side to the "B+" terminal, wrap it securely, and fasten it with a nut. A small amount of conductive paste can be applied to reduce contact resistance. Connect the excitation wire and signal wire to the designated terminals accordingly, taking care to avoid reverse connection. After wiring is completed, reconnect the negative terminal of the vehicle battery.
Manually rotate the pulley to confirm the belt has no deviation or jamming. Start the engine, observe that the generator operates stably without abnormal noise, and check that the belt shows no slipping or vibration.
Use a multimeter to measure the generator output voltage. For 12V vehicle systems, the no-load voltage of the generator should be approximately 13.5-14.5V; for 24V systems, it should be approximately 27-29V. A voltage within this range indicates normal power generation.
Power Disconnection to Prevent Short CircuitsThroughout the installation process, the negative terminal of the vehicle/agricultural machinery battery must be disconnected first (for 24V systems, disconnect the series connection point of the two batteries). This prevents electric sparks during wiring from damaging the generator rectifier or ECU. Reconnect the negative terminal only after wiring is completed.
Protection Against Mechanical InjuriesWear gloves during operation to avoid scratches from pulley edges and bolt sharp corners. Control force when prying the tensioner to prevent tool slippage and impact injuries; the use of special tools with non-slip handles is recommended.
High-Temperature ProtectionIf the engine has just been shut down, wait for the engine temperature to drop below 50℃ before operation to avoid burns from high-temperature components.
8PK Belt CompatibilityUse only 8PK specification belts matching the engine model (including length, width, and tooth profile parameters). Mixing different types of belts (e.g., 6PK, 10PK) is strictly prohibited, as this may cause belt disengagement, pulley groove wear, or reduced power generation efficiency. It is recommended to select brand belts such as Gates or Continental that comply with ISO 9563 standards.
Generator CompatibilityConfirm that the generator mounting feet and pulley diameter fully match the engine bracket. For models such as Sinotruk MAN and Xichai, verify the original factory installation dimensions (refer to the engine maintenance manual) to avoid forced installation that may cause generator body deformation.
Component Condition Inspection
Generator: The pulley rotates without abnormal noise or axial movement; terminal posts are free of rust (oxide layers must be polished to metallic luster with fine sandpaper); bearings operate without jamming.
Pulleys and Tensioner: Crankshaft pulleys and idler pulley grooves show no wear or cracks; the tensioner spring has normal elasticity (if the tensioner stroke is insufficient or reset is jammed, replace the tensioner simultaneously).
Bolts and Washers: Use only original-specification high-strength bolts (Grade 8.8 or higher is recommended) and lock washers (e.g., spring washers, lock nuts). Substitution with ordinary bolts is strictly prohibited to prevent loosening due to long-term vibration.
Pulley Plane AlignmentAfter fixing the generator, use a spirit level or wire-stretching method to check the coplanarity of the generator pulley and crankshaft pulley. The deviation must be ≤0.5mm; otherwise, it may cause belt uneven wear, abnormal noise, or even breakage (refer to GB/T 13575.1 Belt Drive Installation Standards).
Belt Routing and SeatingInstall strictly according to the belt routing mark on the engine block; reverse routing is prohibited. The 8PK belt must be fully seated in all pulley grooves, with no belt tooth tips exposed beyond the groove edges. Otherwise, transmission efficiency will decrease and belt aging will accelerate.
References：
GB/T 13575.1-2008 "Ordinary and Narrow V-Belts - Part 1: Reference Width System"This is an important national standard previously issued for V-belt transmission. Although it was replaced by GB/T 13575.1-2022 on July 1, 2023, the installation requirements in the content—such as pulley coplanarity and belt-pulley groove matching—are all based on the installation and usage specifications for ordinary and narrow V-belt transmission specified in this standard. For example, the standard explicitly prohibits mixing different types of V-belts, which corresponds to the requirement in the precautions that mixing 8PK belts with other models (e.g., 6PK, 10PK) is strictly forbidden.
QC/T 413-2018 "General Standard for Installation of Automotive Electrical Equipment"This is a professional standard in the automotive industry that specifically regulates the installation guidelines for automotive electrical equipment. The electrical-related installation key points and precautions in the content—including the tightening requirements for generator terminal posts, wire selection standards, and grounding specifications—are all based on this standard to ensure the safety and stability of the electrical connections of automotive generators.
Sinotruk MAN MTU Engine Maintenance Manual (TMI 2023 Edition)This edition of Sinotruk MAN’s manual includes detailed installation specifications for generators matched with engine series such as D20 and D26. Content specific to Sinotruk MAN models—such as generator mounting foot matching, torque standards for fixing bolts, and adaptability requirements with the engine pulley system—are all derived from this manual, making it suitable for generator installation scenarios in Sinotruk-related trucks.
Xichai CA6DM3 Series Technical DocumentsThese documents cover the assembly technical requirements for generators matched with CA6DM3 diesel engines. The key points adapted to Xichai models in the content—including the compatibility verification between the generator and the engine, and the wiring specifications for excitation circuits—reference the assembly standards for engines and generators in this series of documents, which are closely aligned with the generator installation needs of vehicles equipped with Xichai models.
Industry-General Installation and Maintenance ExperienceIn addition to the above standards and manuals, some content is derived from industry-general experience in generator installation. For example, commissioning key points such as checking belt deflection by pressing (preferably 1-2 cm) after installation and monitoring the generator housing temperature (≤85℃) after operation, as well as recommendations for special scenarios such as using reinforced 8PK belts for high-load vehicles and preheating belts in winter, are all general specifications summarized from long-term practical experience in generator installation for trucks and agricultural machinery. These specifications are widely applicable to various installation scenarios of generators adapted to 8PK belts.
Related Articles
Can you install an auto starter in any vehicle? Learn how Auto Starter installation works, which cars are compatible, and how manufacturer production and factory supply ensure reliable performance for modern vehicles.....
Discover what vehicles use auto starter systems and how Auto Starter car technology improves safety, convenience, and performance. Learn about manufacturer production, factory supply, and modern applications for cars, trucks, and commercial vehicles.....
Looking for a complete Auto Starter guide? This article explains how auto starters work, types, symptoms, maintenance tips, and how manufacturers and factories supply high-quality starters for global production and bulk orders.....
Learn everything about starter parts, how they work, signs of failure, maintenance tips, and how a professional manufacturer with factory production ensures stable, high-quality starter components for global vehicle owners.....
Explore the real-world Auto Starter disadvantages in industrial and automotive production. Learn how auto starter systems affect reliability, cost, maintenance, and factory manufacturing efficiency.....
Discover what a starter solenoid does in a vehicle, how it works with the starter motor, signs of failure, and why quality starter solenoid production from a professional manufacturer and factory matters for reliable performance.....
