alternator AVi147E AVI147E3001 C5302708 5294335 3701-01497 for Dongfeng Cummins Bus Yutong ZK6899HA/6938HB9

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 zonal 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.

Precautions for the Installation of Dongfeng Cummins 28V Generator

I. Installation Environment Specifications

1. Basic Environmental Requirements: The installation site must be clean, dry, and well-ventilated, away from dust, corrosive gases, flammable and explosive materials. Meanwhile, it should avoid direct sunlight and waterlogged areas. Sufficient space shall be reserved for the generator's air inlet, and the area of the air outlet shall not be less than 1.5 times that of the water tank to ensure heat dissipation efficiency.

2. Safety Distance Control: The minimum distance between the generator set and buildings, walls, and other equipment shall not be less than 1 meter. The exhaust pipe and air outlet shall not be directly facing doors, windows, vents, or personnel activity areas to prevent exhaust gas intrusion and high-temperature scalds.

3. Fire Protection and Protection Configuration: Suitable fire-fighting equipment (such as dry powder fire extinguishers) must be equipped on-site. It is strictly prohibited to stack combustible materials such as oil-soaked rags and cartons nearby. If installed indoors, an effective exhaust gas emission device must be installed to avoid carbon monoxide accumulation.

II. Foundation and Fixing Operations

1. Foundation Quality Control: The concrete foundation must meet the design strength requirements, and the surface flatness error shall not exceed the specification standards. The roughening treatment of the foundation shall be uniform to ensure firm bonding between the grouting layer and the foundation, preventing loosening caused by later vibration.

2. Shock Absorber Installation: Position the shock absorbers strictly according to the drawings to ensure the correct quantity and installation location. There shall be no debris interlayer between the shock absorbers, base plates, and the foundation. After installation, test the shock absorption effect; the vibration amplitude of the unit during operation must be within the allowable range.

3. Grouting Construction Specifications: Use grouting materials that meet the requirements, control the grouting speed and compactness to avoid cavities and cracks. During the curing period, do not touch the unit or conduct subsequent installation operations. Tighten the anchor bolts only after the grouting layer strength meets the standards.

4. Bolt Tightening Standards: The anchor bolts and equipment fixing bolts shall be tightened in stages according to the design torque; the use of a torque wrench is recommended. Flat washers and spring washers must be equipped during bolt installation to prevent loosening due to vibration. Mark the bolts after tightening for subsequent inspection.

III. Electrical Connection Safety

1. Grounding and Lightning Protection Treatment: The unit shell must be reliably grounded for protection, with a grounding resistance not exceeding 4Ω. If the generator requires direct neutral point grounding, the operation must be performed by professional personnel, and an independent grounding system shall be set up. It is strictly prohibited to share the grounding device with the mains power supply. Meanwhile, lightning protection components that meet the specifications shall be configured.

2. Cable Selection and Connection: The cable specifications must match the generator's power and current requirements. Cable joints shall be crimped or welded, wrapped with insulating tape, and provided with waterproof protection. Wiring must strictly follow the wiring diagram, distinguishing between positive and negative poles and control circuits to avoid reverse connection or short circuits.

3. Reliability of Bidirectional Switch: The bidirectional transfer switch connecting the generator and the mains power supply shall be a qualified product with a mechanical interlock function to prevent safety accidents caused by back-feeding of electricity. After wiring, it must pass the inspection of the local power supply department before being put into use.

IV. Pipeline Installation Requirements

1. Exhaust Pipe Installation: The diameter of the exhaust pipe shall not be smaller than that of the muffler outlet. The number of pipe elbows shall not exceed 3, and the elbow angle shall not be less than 90 degrees to reduce exhaust resistance. The pipeline shall be inclined downward by 5°-10°; if installed vertically, a rain cover must be added to prevent rainwater from entering the exhaust pipe and the engine.

2. Fuel and Cooling Pipelines: The fuel pipe shall be an oil-resistant rubber pipe or metal pipe. The joints shall be double-fixed with clamps, and a pressure test shall be conducted after installation to ensure no leakage. The connection of cooling water pipes shall be tightly sealed to avoid engine overheating caused by water leakage. Meanwhile, reserve expansion allowance to prevent pipeline cracking due to vibration.

3. Pipeline Protection Measures: All pipelines shall be kept away from high-temperature components (such as the exhaust pipe) with a spacing of not less than 10 centimeters; heat insulation sleeves shall be added if necessary. The pipeline routing shall be neat to avoid interference with the moving parts of the unit. Use flexible connections for transition to reduce vibration transmission.

4. References：