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Type :
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ENGINE STARTER
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Specification :
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Pulley :
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7PK
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Brand :
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NUOJIN
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Number :
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802B00-3701100SF3
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Quality :
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Remanufacture
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Delivery time :
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30DAY
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This installation method is based on the Yuchai Original Generator Maintenance Manual (No.: YC4D/YC6J Series Engine-matched Generator Installation Specifications) and GB/T 2820.5-2019 General Technical Conditions for Alternators Driven by Reciprocating Internal Combustion Engines. It applies to 28V vehicle-mounted alternators matched with Yuchai diesel engines.
Special Tools: Torque wrench (range: 0–100N·m), socket wrench set, Phillips/flathead screwdriver, multimeter.
Materials: Original generator fixing bolts, lock washers, insulating gaskets, high-temperature resistant grease, electrical insulating tape, threadlocker (Loctite 243).
Inspect the generator appearance: No housing cracks, no bearing jamming or abnormal noise, no oxidation or corrosion on terminal posts.
Verify the generator model: Confirm compatibility with the Yuchai engine model (e.g., models matching YC4S, YC6A series engines).
Check accessories: No aging or cracking of the drive belt, and the tensioner pulley rotates flexibly.
Ensure the engine is shut down and cooled down completely. Disconnect the negative battery cable to prevent short circuits.
Clean the contact surface of the generator mounting bracket on the engine block to remove oil stains and rust, then apply a small amount of high-temperature resistant grease.
Place the generator on the mounting bracket, align the bolt holes, and insert the original fixing bolts with lock washers. Note to distinguish between long bolts (main fixing end) and short bolts (adjusting end).
Tighten the fixing bolts by hand (do not torque them down yet) to reserve adjustment space for belt installation and tensioning.
Install the drive belt: Route the belt around the crankshaft pulley, tensioner pulley and generator pulley in sequence according to the engine pulley routing diagram. Ensure the belt is free of twists and fits snugly in all pulley grooves.
Adjust the tensioner position: Push the generator via the adjusting bolt to achieve the specified belt tension — Press the middle section of the belt (between two pulleys), the deflection should be 10–15mm (in compliance with Yuchai original factory standards).
Tighten the fixing bolts: Use a torque wrench to tighten the bolts to the torque specified by the original factory (generally, the torque for main fixing bolts is 45–55N·m, and for adjusting end bolts is 35–40N·m). Apply threadlocker to the bolt heads to prevent loosening.
Power cable connection: Connect the positive battery cable to the B+ (positive terminal) of the generator, install an insulating gasket, and tighten the nut (torque: 8–10N·m) to ensure good contact.
Control wire connection: Connect the field wire (usually blue or yellow) in the engine wiring harness to the D+ terminal of the generator, and connect the ground wire to the grounding point on the generator housing.
Wiring arrangement: Secure the wiring harness with cable ties, keeping it away from moving parts (e.g., belts) and high-temperature components to prevent abrasion or burnout.
Recheck the belt tension, bolt tightness, and correctness of wiring connections.
Reconnect the negative battery cable and clean up the installation tools and work area.
Start the engine and run it at idle speed for 3–5 minutes. Observe the generator for abnormal noise and check if the belt slips.
Measure the generator output voltage with a multimeter: The voltage should be 28–30V at idle speed, and not less than 27V at full load, meeting the output standards of Yuchai 28V generators.
Shut down the engine and recheck the bolt tightness and wiring connections once again.
These precautions are formulated in accordance with the Yuchai Original Generator Maintenance Manual (No.: YC4D/YC6J Series Engine-matched Generator Installation Specifications) and GB/T 2820.5-2019 General Technical Conditions for Alternators Driven by Reciprocating Internal Combustion Engines, so as to ensure compliance of installation operations and safe operation of equipment.
Disconnect the negative battery cable before installation to prevent short circuits from causing sparks, burning the generator or vehicle electrical components.
Ensure the engine is completely shut down and cooled to avoid scalding by high-temperature components and prevent accidental engine startup.
Verify the compatibility between the generator model and the engine model (e.g., special generator models matching YC4S, YC6A series engines). Do not mix incompatible models.
Inspect the generator appearance: Check for no housing cracks, no bearing jamming or abnormal noise, and no oxidation or corrosion on terminal posts. Inspect the condition of the drive belt and tensioner pulley; replace aging or cracked components in advance.
Use only original factory-matched fixing bolts with lock washers. Do not replace them with non-standard bolts to prevent bolt breakage or generator loosening.
Distinguish between long bolts for the main fixing end and short bolts for the adjusting end; do not install them incorrectly. Apply Loctite 243 threadlocker to the bolts before tightening, and operate according to the specified torque (45–55N·m for main fixing bolts, 35–40N·m for adjusting end bolts). Avoid over-loosening or over-tightening to prevent bracket deformation.
Route the belt strictly in accordance with the engine pulley routing diagram. Ensure the belt is free of twists and fully fits into the pulley grooves. Do not force the belt into place by prying.
Belt tension standard: Press the middle section of the belt (between two pulleys), and control the deflection within 10–15mm. Excessive tension will accelerate bearing wear and cause premature belt breakage; insufficient tension will lead to belt slipping and insufficient power generation.
Connect the power cable (positive battery terminal) to the generator’s B+ terminal, install an insulating gasket, and tighten the nut to a torque of 8–10N·m to ensure secure and non-loose contact.
Connect the field wire (corresponding wire in the engine wiring harness) to the D+ terminal, and reliably connect the ground wire to the grounding point on the generator housing. Do not allow loose connections or incorrect terminal connections.
Arrange the wiring harness and secure it with cable ties. Keep it away from moving parts (e.g., belts) and high-temperature components (e.g., exhaust pipes) to prevent harness abrasion or burnout that could cause short circuits.
Do not strike the generator housing or end caps to avoid damaging internal stator, rotor windings and rectifier bridge components.
Do not touch rotating parts such as pulleys during installation to prevent pinching injuries.
References：
The source description of the "Installation Method & Precautions for Yuchai 28V Generator" document you previously received requires two key clarifications against the officially released versions. The following is an authoritative traceability and explanation.
Nature: This is an identifier for internal/original factory technical documentation cited in my previous response. It is used to anchor model compatibility and key parameters such as bolt torque, belt deflection, and voltage range. As a technical specification for the assembly and maintenance of Yuchai engines and their matched generators, it is generally provided to authorized service stations and original equipment manufacturers (OEMs) along with complete engines or spare parts, and its full text is not available for public download.
Access Methods: If you are a vehicle owner or a repair shop, you may apply to your local authorized Yuchai service station to consult the maintenance manual or installation diagrams for the corresponding engine model. You can also submit the engine serial number through Yuchai's official after-sales channels to obtain the dedicated chapter on generator installation and commissioning.
Nature: This is the national standard number mentioned in my previous response, but it contains an error. In the current valid national standard system, the GB/T 2820 series pertains to Reciprocating Internal Combustion Engine-Driven Alternator Sets. The latest version is GB/T 2820.5-2025 (released on May 30, 2025, and implemented on December 01, 2025), which replaces the old version GB/T 2820.5-2009. Additionally, the standard title should be Part 5: Generator Sets instead of "General Technical Conditions for Alternators".
Purpose: This series of standards specifies the general safety, performance, testing, and installation requirements for generator sets. It serves as the compliance basis for safety operations and performance evaluation in my previous response.
Access Methods: The official text can be purchased or consulted via the China Standards Press or the official website of the Standardization Administration of China.
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