Standard Installation Procedure for XICHAI 6DL2-E3, FAW JIEFANG J6 6DL1 28V Generator

I. Pre-installation Preparation

1. Tools and Materials

2. Vehicle and Component Inspection

1. Park the vehicle on a flat surface, engage the parking brake, turn off the engine, disconnect the negative battery cable and wait for 5–10 minutes to discharge residual power.

2. Verify that the generator model/part number matches the engine, and confirm that the rated voltage is 28V, with power/speed parameters compatible with 6DL1/6DL2-E3 engines.

3. Inspect the generator for no external damage; the bearing should rotate smoothly without jamming or abnormal noise. The rectifier and regulator connections must be intact, and the pulley should be free of deformation.

4. Clean oil stains and rust from the mounting surface of the engine block, check that the fixing bolt holes have no thread damage, and ensure the battery is fully charged with clean terminals.

II. Installation Steps

1. Positioning and Pre-installation

1. Align the generator mounting holes with the engine block, manually screw in 2–3 fixing bolts (do not fully tighten), and ensure the generator pulley is coplanar with the crankshaft pulley, with a deviation ≤ 0.5mm.

2. Check that the generator mounting surface is fully attached to the engine block without gaps; if necessary, install original factory gaskets to adjust flatness.

2. Tightening the Fixing Bolts

1. Use a torque wrench to tighten the bolts in a cross-symmetrical sequence in 2–3 steps. The torque for the fixing bolts of 6DL series generators is 55–60N·m (refer to the engine manual for exact values).

2. Ensure the generator has no deviation or looseness, and the pulley rotates without jamming.

3. Drive Belt Installation and Tension Adjustment

1. Install the drive belt, making sure it aligns with the grooves of all pulleys without twisting.

2. Adjust the belt tension: Press the middle part of the belt, and the deflection should be 10–15mm (standard for FAW JIEFANG J6 6DL series), or use a tension gauge to verify that the tension meets original factory requirements.

3. Tighten the tensioner fixing bolt to a torque of 30–35N·m.

4. Electrical Wiring Connection

1. Check that all connections are secure; wrap exposed parts with insulating tape to prevent short circuits.

2. Apply conductive paste to the wiring terminals, and secure the wire harnesses with cable clips to avoid terminal detachment due to pulling forces.

5. Reset and Functional Testing

1. Reconnect the negative battery cable, apply battery terminal protector and tighten the nut.

2. Turn the ignition switch to the ON position; test that the generator excites normally, and the charging indicator light turns on and then off.

3. Start the engine, check that the generator runs without abnormal noise or vibration, and the belt has no slipping sound.

4. Voltage test: When the engine runs from idle to rated speed, the output voltage should be stably maintained at 27–29V (standard for 28V systems).

5. Load test: Turn on the electrical loads, and confirm that the output current is stable without overheating or smoke.

Precautions for Installation of XICHAI 6DL2-E3, FAW JIEFANG J6 6DL1 28V Generator

I. Safety Precautions Before Installation

1. Power-off Operation Must Be Performed First

1. Prior to installation, be sure to disconnect the negative battery cable and wait for 5–10 minutes to discharge the residual power of the electrical system. Some FAW JIEFANG J6 models are equipped with an ECU backup power supply, which requires an additional 10-minute wait. This prevents electric arcs from occurring when plugging or unplugging wires, which could burn out the generator regulator, rectifier or the vehicle's electronic control system.

2. Do not touch the generator wiring terminals while the battery is connected to avoid the risk of electric shock; it is strictly prohibited to touch the generator B+ terminal (main output) and the housing simultaneously with metal tools to prevent short circuits and component burn-out.

3. The batteries of FAW JIEFANG J6 are mostly installed on the side of the frame. When disconnecting the negative cable, take care to avoid scratching the surrounding wire harnesses, sensor connectors or fuel pipelines with tools; after disconnection, wrap the cable ends with insulating tape to prevent accidental contact and electric conduction.

2. Strict Verification of Component Compatibility

1. Confirm that the OE part number, rated voltage of 28V and power rating of the new generator are fully matched with the 6DL1/6DL2-E3 engines. It is strictly forbidden to mix 12V generators or accessories of other models. The generators for XICHAI 6DL series engines are of special specifications, and incorrect installation will lead to abnormal charging voltage, belt slipping or generator burn-out.

2. Check the condition of the generator bearing: Rotate the pulley by hand, it should rotate smoothly without jamming or abnormal noise. The axial clearance shall be ≤ 0.3mm and the radial clearance shall be ≤ 0.2mm. If the clearance exceeds the limit, replace the generator assembly. Disassembly and repair are prohibited (the original factory generator has a sealed structure, and the insulation performance cannot be guaranteed after disassembly).

3. Verify the model of the generator regulator. The 6DL2-E3 engine is compatible with intelligent voltage-regulating regulators, which need to be compatible with the vehicle power management system. Ordinary regulators cannot meet the electrical control requirements of National III emission standard models.

4. References：
   

5. The following is the authoritative source tracing and clause correspondence instructions for the above-mentioned precautions, ensuring that the content is compliant and verifiable.

7. I. Core Authoritative Sources and Acquisition Channels

9. Source Name	Publisher	Core Basis	Acquisition Channels
   XICHAI 6DL Series Engine Original Factory Maintenance Manual (Chapters on Electrical System and Engine Mechanics)	Wuxi Diesel Engine Works, FAW Jiefang Automotive Co., Ltd.	Generator installation procedures, fixing bolt torque (55–60N·m), belt tension/deflection (10–15mm), definitions and torque values of B+/F/N terminals (15N·m for main terminal, 5–8N·m for excitation terminal, 10–12N·m for ground terminal), component compatibility requirements, mounting surface flatness/coaxiality requirements	FAW Jiefang authorized dealers, XICHAI after-sales service system, original factory technical data platform
   QC/T 413-2002 Basic Technical Requirements for Automobile Electrical Equipment	Former State Economic and Trade Commission (now the Ministry of Industry and Information Technology of the People's Republic of China), under the jurisdiction of the National Technical Committee for Standardization of Automobiles	Electrical safety regulations, installation fit tolerances, component adaptation criteria, electrical connection specifications, reliability testing and fault judgment guidelines	National Public Service Platform for Standard Information, automotive industry standard databases such as ChineseStandard.net, Antpedia, etc.

11. II. Clause Correspondence Instructions

13. Precaution Module	Corresponding Clauses in Authoritative Sources
    Power-off operation & component compatibility verification	Safety specification chapter of XICHAI 6DL Maintenance Manual, electrical safety and component adaptation clauses of QC/T 413-2002
    Cross-symmetrical bolt tightening & torque parameters	Torque specification chapter of XICHAI 6DL Maintenance Manual, installation and tightening requirements of QC/T 413-2002
    Drive belt installation and tension adjustment	Accessory drive system chapter of XICHAI 6DL Maintenance Manual, electrical equipment installation environment and transmission requirements of QC/T 413-2002
    Definition and torque requirements of electrical terminals	Electrical connection chapter of XICHAI 6DL Maintenance Manual, terminal connection specifications of QC/T 413-2002
    Post-installation testing process & fault judgment	Function verification chapter of XICHAI 6DL Maintenance Manual, reliability testing and fault judgment guidelines of QC/T 413-2002
    Inspection of mounting surface and surrounding components	Mechanical installation parameter chapter of XICHAI 6DL Maintenance Manual, electrical equipment installation environment requirements of QC/T 413-2002

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