alternator 4938300 C4938300 ALQ6924BJ、ALQ6924UW for Cummins EQ153 [6BT 4BT]

Pre-installation Preparation

1. Confirm the Installation Environment: Select a well-ventilated location free of flammable and explosive materials. The ground should be flat and have sufficient load-bearing capacity.

2. Prepare Installation Tools: Prepare tools such as screwdrivers, wrenches, and a level.

3. Inspect the Generator: Check that the generator and its accessories are intact and meet the installation requirements.

Foundation Installation

1. Foundation Setting Out and Treatment: Clean the debris on the concrete foundation and in the reserved holes for anchor bolts. Recheck the elevation, dimensions, and position of the equipment foundation. Mark the equipment installation reference line and the center line of the anchor bolt positions, and roughen the concrete foundation.

2. Shock Absorber Installation: Place the shock absorbers on the corresponding base plates according to the drawings. Tighten the connecting bolts with the base plates, and then retighten them to the designed torque after grouting the anchor bolt holes. Adjust the installation position and elevation of the shock absorbers to ensure there is no obvious gap between the shock absorbers and the base plates.

3. Grouting of Anchor Bolt Holes and Post-grouting Inspection: After confirming that all technical parameters of the diesel engine, base plates, and shock absorber installation meet the requirements, grout the anchor bolt holes. After the curing period, initially tighten the anchor bolts. After the curing period of the secondary grouting, tighten the anchor bolts to the designed torque, remove the temporary shim plates, and re-inspect the equipment.

4. Secondary Grouting of Equipment: According to the manufacturer's technical requirements, control the elevation and area of the secondary grouting. The compartmental grouting method can be adopted to ensure the grouting quality.

Generator Installation

1. Fix the Generator Base: Place the generator base at the installation position, adjust it to be level using a level, and then fix the base to the ground with screws.

2. Install the Generator Body: Place the generator body on the base, ensure the contact surface is flat, and fix the generator body to the base with screws.

Connection of System Components

1. Connect Cables: According to the generator wiring diagram, select appropriate cables and connect them correctly. Ensure the cable joints are tight and free of looseness, and pay attention to the polarity and sequence of connections.

2. Install the Exhaust Pipe: Install the exhaust pipe as required to ensure smooth exhaust and prevent backfire. The joints should be tight to avoid exhaust gas leakage.

3. Install the Fuel Pipe: Install the fuel pipe to ensure sufficient fuel supply and no leakage.

4. Connect the Cooling System: Connect the cooling water pipes according to the cooling system installation requirements to ensure unobstructed circulation of cooling water.

Inspection and Commissioning

1. Visual Inspection: Check that the generator appearance is intact without damage or deformation.

2. Cable Inspection: Check that the cable connections are tight without looseness or damage.

3. Fuel and Oil Inspection: Check that the fuel and oil are sufficiently filled without leakage.

4. Cooling System Inspection: Check that the cooling water circulation is unobstructed without leakage.

5. Operation Test: Start the generator, observe whether it operates stably without abnormal noise or vibration. Check if the charging indicator light turns off normally, and use a multimeter to measure the battery voltage to ensure it is within the normal range.

Installation Environment Selection

• Clean, Dry and Well-ventilated: The installation site should be kept clean, free from harmful gases, liquids, dust, metallic dust, combustibles or explosives, etc. The environment should be dry and well-ventilated. The generator end should have sufficient air inlets, and the diesel engine end should have good air outlets. The area of the air outlet should be more than 1.5 times the area of the water tank.

• Away from Flammable Materials: It is strictly prohibited to place items that can produce acidic, alkaline and other corrosive gases and vapors nearby. If possible, fire-fighting equipment should be equipped.

• Maintain a Safe Distance: The distance between the generator set and buildings or other structures should be at least more than 1 meter. The exhaust outlets and exhaust pipes should not face the doors or windows of buildings or structures directly.

Basic Installation Requirements

• Levelness Detection: When the foundation is made of concrete, a level should be used during installation to measure its levelness, so that the unit is fixed on a horizontal foundation.

• Shock Absorption Treatment: There should be special shock-absorbing pads or anchor bolts between the unit and the foundation to reduce the impact of vibration on the unit and the foundation.

Electrical Connection Precautions

• Protective Grounding: The casing of the unit must have a reliable protective ground. For generators that require a neutral point to be directly grounded, the neutral grounding must be carried out by professional personnel, and a lightning protection device should be configured. It is strictly prohibited to use the grounding device of the utility power for the direct grounding of the neutral point.

• Reliable Bidirectional Switch: The bidirectional switch between the generator and the utility power must be very reliable to prevent back-feeding. The wiring reliability of the bidirectional switch needs to be inspected and approved by the local power supply department.

Exhaust Pipe Installation

• Pipe Leading to the Outside: When used indoors, the exhaust pipe must be led to the outside. The pipe diameter must be ≥ the diameter of the exhaust pipe of the silencer, and the number of elbows in the connected pipeline should not be more than 3 to ensure smooth exhaust.

• Prevent Rainwater from Inflowing: The pipe should be tilted downward by 5-10 degrees to prevent rainwater from inflowing. If the exhaust pipe is installed vertically upward, a rain cover must be installed.

Other Precautions

• Tool Use: Reasonably use tools, measuring tools and special tools to ensure the assembly quality. For example, use a torque wrench to control the tightening torque of bolts.

• Component Installation: When installing the water-stop ring, do not apply oil. A little white paint or soapy water can be applied to facilitate assembly. When installing the piston ring, do not apply butter. The steel ball of the speed control plate should not be stained with butter, and the mating conical surface of the flywheel and the crankshaft should not be coated with butter.

• Pipeline Connection: All pipelines such as fuel, water, and exhaust gas pipelines and electrical connections should have flexible connections as transitions to avoid failures caused by the vibration of the generator set.

References：The content provided above may be comprehensively referenced from the official Cummins website, professional automotive repair websites, technical materials related to diesel generators, and some engineering documents. For example, the Cummins China official website (m.cn-cummins.com) has relevant content on the installation key points of Cummins generators. Cummins Power (Shenzhen) Co., Ltd. has also released the installation technical specifications and key points of diesel generators, which involve some specific operations and precautions during the installation process.